Disposable absorbent articles having multiple absorbent core components including replaceable components

ABSTRACT

A disposable absorbent article adapted to be worn about a lower torso of a human body and having a chassis, a non-removable absorbent core component disposed in a crotch region of the chassis, and a replaceable absorbent core component disposed in capillary liquid communication with the non-removable absorbent core component. The replaceable absorbent core component may be removed and a like component may be substituted in place of the removed component without the removal of the absorbent article from the wearer. The replaceable absorbent core component may be disposed inside an openable chassis pocket, with access for its removal and replacement provided by an aperture in a backsheet, an openable end of an external pocket, or an openable end of an internal pocket formed at an area of a waist end edge where the backsheet and a topsheet may be separated. Additional replaceable absorbent core components may also be incorporated.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 10/308,430filed on 3 Dec. 2002 now U.S. Pat. No. 7,670,324, which was acontinuation-in-part of application Ser. No. 09/911,108 filed on 23 Jul.2001, now U.S. Pat. No. 6,932,800, which in turn was acontinuation-in-part of application Ser. No. 09/431,322 filed on 2 Nov.1999, now abandoned, which in turn was a continuation of applicationSer. No. 08/825,071 filed on 27 Mar. 1997, now U.S. Pat. No. 6,015,935.Application Ser. No. 10/308,430 was also a continuation-in-part ofapplication Ser. No. 08/828,005 filed on 27 Mar. 1997, now U.S. Pat. No.6,989,005. All of the above-identified priority documents are herebyincorporated in their entirety herein by reference.

FIELD OF THE INVENTION

This invention relates to disposable absorbent articles, such asdisposable diapers and particularly to disposable absorbent articleshaving multi-piece absorbent cores in which some absorbent corecomponents are non-removable and other absorbent core components areremovable and replaceable.

BACKGROUND OF THE INVENTION

Disposable absorbent articles such as disposable diapers, incontinencepads, training pants, and catamenial napkins generally include anabsorbent core for receiving and holding bodily exudates. The absorbentcore typically includes a fibrous web, which can be a nonwoven, airlaidweb of natural or synthetic fibers, or combinations thereof. Fibrouswebs used in such absorbent articles also often include certainabsorbent gelling materials usually referred to as “hydrogels”,“superabsorbents”, or “hydrocolloid” materials to store large quantitiesof the discharged bodily liquids. These materials absorb throughcapillary or osmotic forces, or a combination of both.

Many absorbent articles such as catamenial pads, adult incontinentproducts, and diapers are subject to leakage due to an inability toabsorb second and subsequent discharges of liquid even if the firstliquid discharge has been effectively absorbed. Leakage due to secondand subsequent discharges is especially prevalent during the night, whenusers commonly experience multiple discharges before the absorbentarticle is changed. One reason for the inability of many absorbentarticles to adequately handle multiple discharges of liquid is theinability of the absorbent core to transport discharged liquid away fromthe region of discharge once the absorbent capacity of that region hasbeen reached. Thus, the overall performance of the absorbent article islimited by the inability to transport the liquid to the farthest reachesof the absorbent core.

An alternative absorbent material capable of providing capillary liquidtransport is open-celled polymeric foam. Appropriately made open-celledpolymeric foams provide features of capillary liquid acquisition,transport, and storage required for use in high performance absorbentcores for absorbent articles such as diapers. Shaped or contouredabsorbent cores made from such open-celled foam materials havingparticularly desirable liquid transport characteristics are disclosed inU.S. Pat. No. 5,147,345 issued to Young et al. on Sep. 15, 1992. TheYoung et al. '345 absorbent core includes both a liquidacquisition/distribution member and a liquid storage/redistributionmember. The liquid acquisition/distribution member is positioned withinthe absorbent article in such a way as to receive or contact aqueousbodily liquid which has been discharged into the absorbent article bythe wearer of the article. The liquid storage/redistribution member, inturn, is positioned within the article to be in capillary liquidcommunication with the liquid acquisition/distribution member.

Absorbent cores providing the desirable absorbent characteristics of theYoung et al. '345 patent in an exemplary multi-piece configuration aredisclosed in U.S. Pat. No. 5,906,602 issued to Weber et al. on 25 May1999, which describes shaped absorbent cores having a front panel and aback panel in capillary liquid communication with a center section. Thecenter section includes material generally suitable for liquidacquisition/distribution, while the front and back panels includematerial generally suitable for liquid storage/redistribution.

Despite the advances in absorbent articles and in liquid handlingabsorbent core materials, absorbent articles having multiple absorbentcore components as well as those having unitary absorbent cores aregenerally designed for single use wear. Once the storage/redistributionmember is saturated with bodily discharges, such as urine, the entireabsorbent article is generally discarded and replaced. Often parts ofthe absorbent article are still usable, and except for being unitarywith the absorbent core, these parts could be used further. In additionto the added cost and waste associated with discarding reusablematerials, it is often inconvenient to remove and replace the entireabsorbent article when absorbent core components are saturated.

Absorbent articles having removable absorbent inserts and thereby beingpotentially usable for more than a single use are known in the art. Forexample, U.S. Pat. No. 4,597,761 to Buell, issued Jul. 1, 1986,discloses a disposable absorbent insert for use inside an over-garmentsuch as a conventional reusable diaper, or a disposable diaper. Once theabsorbent insert becomes saturated it may be removed and discarded. Theabsorbent article may then be reused with a fresh absorbent insert.However, because the absorbent insert is removable only from the bodyside of the article, the absorbent article must be removed from thewearer in order to remove the insert. Therefore, the removal of theabsorbent insert is often inconvenient and time consuming.

Accordingly, it would be desirable to provide an absorbent articlehaving a replaceable absorbent core component wherein the absorbent corecomponent can be replaced without having to remove the absorbent articlefrom the wearer.

Additionally, it would be desirable to provide an absorbent articlehaving a replaceable absorbent core component and an aperturedbacksheet, allowing a saturated component of the absorbent core to beremoved through the backsheet aperture, thereby exposing an unsaturatedcomponent and allowing for prolonged use of the reusable portions of theabsorbent article.

Furthermore, it would be desirable to provide an absorbent articlehaving a replaceable absorbent core component disposed between atopsheet and a backsheet, configured such that access to the replaceableabsorbent core component is gained by separating the topsheet and thebacksheet in a predetermined area to form an opening.

SUMMARY OF THE INVENTION

The present invention provides a disposable absorbent article adapted tobe worn about a lower torso of a human body, including a chassis forminga waist opening and a pair of leg openings and having longitudinallyopposed waist end edges, longitudinally opposed waist regions, and acrotch region longitudinally intermediate of the waist regions, anon-removable absorbent core component disposed in the crotch region,and a replaceable absorbent core component disposed in capillary liquidcommunication with the non-removable absorbent core component.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the present invention, it is believed that thepresent invention will be better understood from the followingdescription in conjunction with the accompanying Drawing Figures, inwhich like reference numerals identify like elements, and wherein:

FIG. 1 is a plan view of an exemplary diaper of the present invention inits flat-out, uncontracted state, i.e., with all elastic inducedcontraction pulled out, with portions of the structure being cut away tomore clearly show the construction of the diaper, and with the portionof the diaper that contacts the wearer facing the viewer;

FIG. 2 is an exploded perspective view depicting an exemplary absorbentarticle, with the portion of the article that contacts the wearer facingupward;

FIG. 3 is a perspective, partially segmented illustration of anexemplary diaper embodiment of an absorbent article according to thepresent invention;

FIG. 4 is a side view, showing in partial cross-section, the exemplaryabsorbent article of FIG. 3;

FIG. 5 is an exploded perspective view depicting the relationshipbetween the elements of an exemplary absorbent core of the presentinvention, with the portion of the core that faces the wearer facingupward;

FIG. 6 shows a top plan view of an exemplary absorbent core useful in anabsorbent article according to the present invention;

FIG. 7 is a sectional view of an exemplary absorbent core similar tothat shown in FIG. 6, taken along line 7-7, with the portion of the corethat faces the wearer oriented upward;

FIG. 8 shows a sectional view of another alternative exemplary absorbentcore, with the portion of the core that faces the wearer orientedupward;

FIG. 9 shows a section view of another alternative exemplary absorbentcore, with the portion of the core that faces the wearer orientedupward;

FIG. 10 shows a section view of another alternative exemplary absorbentcore, with the portion of the core that faces the wearer orientedupward;

FIG. 11 is an exploded, perspective, partially segmented illustration ofan alternative exemplary absorbent article according to the presentinvention;

FIG. 12 is a side view, showing in partial cross-section, anotheralternative exemplary absorbent article;

FIG. 13 is a cross-section illustration of a portion of an exemplaryabsorbent article having an opening through the backsheet;

FIG. 14 is a cross-section detail of an exemplary configuration ofremovable and replaceable absorbent core layers;

FIG. 15 is a cross-section detail of an alternative exemplaryconfiguration of a removable and replaceable absorbent core component;

FIG. 16 is a cross-section depiction of an additional alternativeexemplary configuration of removable and replaceable absorbent corelayers.

FIG. 17 is a plan view of another exemplary diaper of the presentinvention in its flat-out, uncontracted state, i.e., with all elasticinduced contraction pulled out, with portions of the structure being cutaway to more clearly show the construction of the diaper, and with theportion of the diaper that contacts the wearer facing the viewer,showing an apertured topsheet;

FIG. 18 is a cross-section view of an exemplary pants-type diaper havingan apertured topsheet.

FIG. 19 is a back view of a diaper embodiment having two layeredwaistbands.

FIG. 20 is a section view of the embodiment of FIG. 19.

FIG. 21 is a back view of a diaper embodiment having two side-by-sidewaistbands.

FIG. 22 is a section view of the embodiment of FIG. 21.

FIG. 23 is a back view of a diaper embodiment having an aperturedwaistband.

FIG. 24 is a section view of the embodiment of FIG. 23.

FIG. 25 is a back view of a diaper embodiment having two side-by-sidewaistbands in different layers.

FIG. 26 is a section view of the embodiment of FIG. 25.

FIG. 27 is a partial section view showing chassis layers andnon-removable absorbent core layers in relation to a replaceableabsorbent core component.

FIG. 28 is a plan view of another exemplary diaper of the presentinvention in its flat-out, uncontracted state, i.e., with all elasticinduced contraction pulled out, with portions of the structure being cutaway to more clearly show the construction of the diaper, and with theportion of the diaper that contacts the wearer facing the viewer,showing a chassis pocket having a separator;

FIG. 29 is a simplified plan view illustrating the method of determiningthe crotch point of an absorbent article;

FIG. 30 is an exploded view of the layers of a replaceable absorbentcore component;

FIG. 31 is a view of the layers of FIG. 30 in a stacked arrangement;

FIG. 32 is a plan view showing a replaceable absorbent core componentillustratively divided into four longitudinal segments;

FIG. 33 is a plan view showing an absorbent layer of a replaceableabsorbent core component illustratively divided into four longitudinalsegments;

FIG. 34 is a plan view showing another absorbent layer of a replaceableabsorbent core component illustratively divided into four longitudinalsegments;

FIG. 35 is a partial section view showing an extensible covering layerin an unextended state;

FIG. 36 is a partial section view showing the extensible covering layerof FIG. 35 in an extended state;

FIG. 37 is a partial section view showing a folded extensible coveringlayer in an unextended state;

FIG. 38 is a partial section view showing the folded extensible coveringlayer of FIG. 37 in an extended state;

FIG. 39 is a plan view showing a replaceable absorbent core componenthaving a pull tab at its outer end;

FIG. 40 is a plan view showing another replaceable absorbent corecomponent having a pull ring at its outer end;

FIG. 41 is a plan view showing a replaceable absorbent core componenthaving an insertion depth indicator;

FIG. 42 is a plan view showing a replaceable absorbent core componenthaving a graphical object insertion depth indicator in a partiallyinserted state;

FIG. 43 is a plan view showing the replaceable absorbent core componentof FIG. 42 in a fully inserted state;

FIG. 44 is a plan view showing a replaceable absorbent core componenthaving another graphical object insertion depth indicator in a partiallyinserted state;

FIG. 45 is a plan view showing the replaceable absorbent core componentof FIG. 44 in a fully inserted state;

FIG. 46 is a partial section view showing a replaceable absorbent corecomponent having a mechanical insertion depth indicator;

FIG. 47 is a partial section view showing a replaceable absorbent corecomponent having another mechanical insertion depth indicator;

FIG. 48 is a partial section view showing a replaceable absorbent corecomponent having directional coefficient of friction elements in aproper end-to-end orientation;

FIG. 49 is a partial section view showing the replaceable absorbent corecomponent of FIG. 48 in an improper end-to-end orientation;

FIG. 50 is a partial section view showing a replaceable absorbent corecomponent having directional coefficient of friction elements in aproper orientation of its wearer-facing and garment-facing surfaces;

FIG. 51 is a partial section view showing the replaceable absorbent corecomponent of FIG. 50 in an improper orientation of its wearer-facing andgarment-facing surfaces;

FIG. 52 is a partial section view showing a replaceable absorbent corecomponent having directional coefficient of friction elements in aproper orientation of both its wearer-facing and garment-facing surfacesand its inner and outer ends;

FIG. 53 is a partial section view showing a replaceable absorbent corecomponent of FIG. 52 in an improper orientation of its wearer-facing andgarment-facing surfaces and a proper orientation of its inner and outerends;

FIG. 54 is a partial section view showing the replaceable absorbent corecomponent of FIG. 52 in an improper orientation of both its inner andouter ends and its wearer-facing and garment-facing surfaces;

FIG. 55 is a partial section view showing the replaceable absorbent corecomponent of FIG. 52 in an improper orientation of its inner and outerends and a proper orientation of its wearer-facing and garment-facingsurfaces;

FIG. 56 is a plan view showing a replaceable absorbent core componenthaving a relatively shallow insertion pocket on its outer surface;

FIG. 57 is a partial section view showing the replaceable absorbent corecomponent of FIG. 56;

FIG. 58 is a plan view showing a replaceable absorbent core componenthaving a relatively deep insertion pocket on its outer surface;

FIG. 59 is a partial section view showing the replaceable absorbent corecomponent of FIG. 58;

FIG. 60 is a plan view showing a replaceable absorbent core componenthaving intermittent linear bonds attaching an insertion pocket to itsouter surface;

FIG. 61 is a plan view showing a replaceable absorbent core componenthaving spot bonds attaching an insertion pocket to its outer surface;

FIG. 62 is a plan view showing a replaceable absorbent core componenthaving continuous linear bonds attaching an insertion pocket to itsouter surface;

FIG. 63 is a plan view showing a replaceable absorbent core componenthaving a rectangular inner end and an insertion pocket on its outersurface;

FIG. 64 is a partial section view showing a replaceable absorbent corecomponent having two relatively shallow insertion pockets on its twomajor surfaces;

FIG. 65 is a partial section view showing a replaceable absorbent corecomponent having two relatively deep insertion pockets on its two majorsurfaces;

FIG. 66 is a partial section view showing a replaceable absorbent corecomponent folded inside an extensible insertion pocket layer fordisposal;

FIG. 67 is a partial section view showing a replaceable absorbent corecomponent having an insertion pocket sheet in its initial pocket-formingconfiguration;

FIG. 68 is a partial section view showing the insertion pocket sheet ofFIG. 67 folded over the inner end of the replaceable absorbent componentto cover a permeable region for disposal;

FIG. 69 is a partial section view showing a replaceable absorbent corecomponent having a covering sheet wrapping over its inner end;

FIG. 70 is a partial section view showing a replaceable absorbent corecomponent having a covering sheet wrapping over its inner end andforming an insertion pocket;

FIG. 71 is a partial section view showing a replaceable absorbent corecomponent having an internal insertion pocket formed between absorbentlayers;

FIG. 72 is a partial section view showing a replaceable absorbent corecomponent having an internal insertion pocket formed between anabsorbent layer and an inner layer;

FIG. 73 is a partial section view showing a replaceable absorbent corecomponent having an internal insertion pocket formed between two innerlayers;

FIG. 74 is a partial section view showing a replaceable absorbent corecomponent having an internal insertion pocket and an inverting pull tabin its initial state;

FIG. 75 is a partial section view showing the replaceable absorbent corecomponent of FIG. 74 in its inverted state;

FIG. 76 is a plan view showing a replaceable absorbent core componenthaving a liquid presence indicator including wicking strips;

FIG. 77 is a plan view showing a replaceable absorbent core componenthaving a liquid presence indicator including an indicating compositiondisposed on an absorbent layer;

FIG. 78 is a plan view showing a replaceable absorbent core componenthaving a liquid presence indicator in the form of a stationary absorbentstrip indicating a wetted area;

FIG. 79 is a plan view showing a replaceable absorbent core componenthaving a liquid presence indicator in the form of a stationary absorbentstrip including a series of visible liquid presence indication means;

FIG. 80 is a plan view showing a replaceable absorbent core componenthaving a “dipstick” type liquid presence indicator in its fully insertedposition;

FIG. 81 is a plan view showing the “dipstick” type liquid presenceindicator of FIG. 80 in its partially withdrawn position;

FIG. 82 is a plan view showing a replaceable absorbent core componenthaving a series of visible liquid presence indication means on a“dipstick” type liquid presence indicator;

FIG. 83 is a plan view showing a replaceable absorbent core componenthaving a liquid presence indicator covered by a movable indicator strip;

FIG. 84 is a plan view showing the liquid presence indicator of FIG. 83after the movable indicator strip has moved to uncover it;

FIG. 85 is a plan view showing a replaceable absorbent core componenthaving a liquid presence indicator disposed on a movable indicator stripand in its initial hidden state;

FIG. 86 is a plan view showing the liquid presence indicator of FIG. 85after the movable indicator strip has moved to reveal it;

FIG. 87 is a plan view showing a replaceable absorbent core componenthaving an insertion tool disposed in an insertion pocket;

FIG. 88 is a plan view showing a replaceable absorbent core componenthaving another insertion tool disposed in an insertion pocket;

FIG. 89 is a plan view showing a replaceable absorbent core componenthaving another insertion tool disposed in an insertion pocket;

FIG. 90 is a partial section view showing the replaceable absorbent corecomponent of FIG. 89;

FIG. 91 is a plan view showing a replaceable absorbent core componenthaving a rectangular inner end and having another insertion tooldisposed in an insertion pocket;

FIG. 92 is a plan view showing a replaceable absorbent core componenthaving a rectangular inner end and having another insertion tooldisposed in an insertion pocket;

FIG. 93 is a partial section view showing a replaceable absorbent corecomponent having two insertion tools disposed in two insertion pocketson its two major surfaces;

FIG. 94 is a partial section view showing a replaceable absorbent corecomponent having an insertion tool joined to it through an intermediatemember in its configuration for insertion;

FIG. 95 is a partial section view showing the replaceable absorbent corecomponent of FIG. 94 having the insertion tool joined to it through theintermediate member in its partially detached configuration duringwithdrawal of the insertion tool;

FIG. 96 is a side elevation view showing an insertion tool formed by acard-like element attached to a bag-like element;

FIG. 97 is a side elevation view showing an insertion tool formed by twocard-like elements attached to a bag-like element;

FIG. 98 is an elevation view showing one major surface of the insertiontool of FIG. 97;

FIG. 99 is a partial section view showing a replaceable absorbent corecomponent disposed inside an insertion tool pocket in an insertion toolconfigured for insertion;

FIG. 100 is a plan view showing one major surface of the insertion toolof FIG. 99 containing the replaceable absorbent core component;

FIG. 101 is a plan view showing an insertion tool having a relativelythicker inner end portion;

FIG. 102 is an edge view showing the insertion tool of FIG. 101;

FIG. 103 is a plan view showing another insertion tool having arelatively thicker inner end portion;

FIG. 104 is an edge view showing the insertion tool of FIG. 103;

FIG. 105 is a plan view showing another insertion tool having arelatively thicker inner end portion;

FIG. 106 is an edge view showing the insertion tool of FIG. 105;

FIG. 107 is a plan view showing a replaceable absorbent core componentand an insertion tool having a longitudinal slot; and

FIG. 108 is a plan view showing a replaceable absorbent core componenthaving a longitudinal slot and an insertion tool having two finger-likesections.

DETAILED DESCRIPTION OF THE INVENTION

The disclosures of all patents, patent applications and any patentswhich issue thereon, as well as any corresponding published foreignpatent applications, and all publications listed and/or referencedhereafter in this description, are hereby incorporated herein byreference. It is expressly not admitted, however, that any of thedocuments or any combination of the documents incorporated herein byreference teaches or discloses the present invention. To the extent thatany meaning or definition of a term assigned herein conflicts with anymeaning or definition of the same term in a document incorporated byreference, the meaning or definition assigned herein governs.

List of U.S. Patent References

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The following definitions of terms may be useful for understanding thedisclosure of the present invention.

-   -   Absorbent article: A device that absorbs and contains bodily        exudates by means of an absorbent core, and, more specifically,        a device which is placed against or in proximity to the body of        a wearer to absorb and contain the various exudates discharged        from the body. An exemplary embodiment of an absorbent article        of the present invention is the disposable absorbent article,        diaper 60, as shown in the drawing figures. It should be        understood, however, that the present invention is also        applicable to other absorbent articles such as incontinence        briefs, incontinence undergarments, diaper holders and liners,        training pants, pull-on diapers, and the like.    -   Absorbent core: An element of an absorbent article containing a        material or a combination of materials suitable for absorbing,        distributing, and storing aqueous liquids such as bodily        exudates.    -   Absorbent core component: A structural constituent of an        absorbent core, e.g., a piece of an absorbent core, such as one        of multiple pieces in a multi-piece absorbent core.    -   Absorbent layer: A term referring to a discrete, identifiable        sheet-like or web-like element of an absorbent core structure        which may remain detached and relatively movable with respect to        another such element or may be bonded or joined so as to remain        permanently associated with another such element. Each absorbent        layer may itself include a laminate or combination of several        sheets or webs of similar or diverse compositions.    -   Absorbent member: A functional constituent of an absorbent core,        e.g., a liquid acquisition member, a liquid        acquisition/distribution member, or a liquid        storage/redistribution member formed of a material or materials        having particular liquid handling characteristics suitable for        the specific function.    -   Absorbent insert: A device adapted for insertion into an        absorbent article and to serve as an absorbent core component        when so inserted. A replaceable absorbent core component is an        absorbent insert, the latter term being especially descriptive        when referring to the device alone.    -   Chassis: A foundational constituent of an absorbent article upon        which the remainder of the structure of the article is built up        or overlaid, e.g., in a diaper, the structural elements that        give the diaper the form of briefs or short pants when        configured for wearing, such as a backsheet, a topsheet, or a        combination of a topsheet and a backsheet.    -   Diaper: An absorbent article generally worn by infants and        incontinent persons about the lower torso of the wearer.    -   Disposable: A term used to describe absorbent articles that are        not intended to be laundered or otherwise restored or reused as        an absorbent article after use, i.e., that are intended to be        discarded after a single use and, preferably, to be recycled,        composted or otherwise disposed of in an environmentally        compatible manner. Note that, as described in this disclosure, a        single use of a chassis and a non-removable core component may        correspond to several uses and replacements of replaceable core        components.    -   Capillary liquid communication: The flow of a liquid from one        absorbent element to another absorbent element by capillary        transport. Also, a term used to describe a structural        disposition of absorbent elements in which the flow of a liquid        from one of the absorbent elements to the other occurs through        capillary transport of the liquid, generally requiring either        the direct face-to-face contact of the absorbent elements with        each other, the direct face-to-face contact of each of the        absorbent elements with a hydrophilic intermediate layer        providing capillary conduction of the liquid from one absorbent        element to the other, or the protrusion of the fibers of a        fibrous absorbent element through a porous and/or permeable        intermediate layer into contact with the other absorbent        element.    -   Join, joined, joining: Terms encompassing configurations wherein        an element is directly secured to another element by affixing        the element directly to the other element, as well as        configurations wherein the element is indirectly secured to the        other element by affixing the element to an intermediate member        or members which in turn is or are affixed to the other element.    -   Major surface: A term used to describe the surfaces of greatest        extent of a generally planar or sheet-like structural element        and to distinguish these surfaces from the minor surfaces of the        end edges and the side edges, i.e., in an element having a        length, a width, and a thickness, the thickness being the        smallest of the three dimensions, the major surfaces are those        defined by the length and the width and thus having the greatest        extent.    -   Replaceable: A term used to describe a component of an absorbent        article that can be replaced, that is, a component that can be        removed and for which a like component can be substituted in        place of the removed component, e.g., a replaceable absorbent        core component or absorbent insert.    -   Stratum, stratified: Terms referring herein to overlying or        superimposed regions within a given layer or structure which        have identifiably diverse compositions, densities, or other        material properties such that the layer or structure is        non-homogeneous through a cross section from one surface to an        opposing surface.    -   Wearer-facing layer: The elements of the chassis that form the        inner surface of the absorbent article, such as the topsheet,        the leg cuffs, and the side panels, etc., when such elements are        present.    -   Garment-facing layer: The elements of the chassis that form the        outer surface of the absorbent article, such as the backsheet,        the side panels, the waist fasteners, and the like, when such        elements are present.        Overall Description

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

As described below in detail, the present invention relates to absorbentarticles suitable for absorbing and retaining aqueous bodily liquids.These absorbent articles of the present invention generally include abacksheet formed of a substantially liquid impervious material and anabsorbent core disposed adjacent to the backsheet. The absorbent coreincludes at least one removable core component disposed in capillaryliquid communication with at least one non-removable core component. Theremovable core component may be inserted into the absorbent articleprior to the application of the absorbent article to the wearer or whilethe absorbent article is being worn. When the removable core componentor a member of it is removed, a replacement absorbent core component ormember may be inserted in place of the removed component or member.

In some exemplary embodiments, the absorbent article may include aplurality of absorbent core components, including a front panel and arear panel in capillary liquid communication with a center section. Eachof the absorbent core components may include multiple absorbent layers.Upon saturation with bodily discharges, removable components orabsorbent layers of the absorbent core may be removed from the absorbentarticle. New, unsaturated absorbent core components or absorbent layersmay then be positioned in place of the removed saturated core componentsor absorbent layers.

In some exemplary embodiments, the removable core component is disposedadjacent to the body-facing surface of the backsheet and is accessiblethrough an aperture in the backsheet. In other exemplary embodiments,the removable core component is disposed adjacent to the garment-facingsurface of the backsheet and is contained in a pocket formed by a pieceof sheet material affixed to the outer surface of the backsheet.

In some exemplary embodiments, the absorbent article includes a liquidpervious topsheet and a substantially liquid impervious backsheet joinedto the topsheet about the periphery of the absorbent article. In apredetermined area of the periphery, the topsheet and the backsheet maybe separated to form an opening providing access to a removable corecomponent disposed between the topsheet and the backsheet and for theinsertion of a replacement core component.

In these exemplary embodiments, the center absorbent core componentpreferably has suitable liquid acquisition and/oracquisition/distribution characteristics, while the front and rearabsorbent core panels or components preferably have suitablestorage/redistribution characteristics.

Exemplary Diaper Embodiment

FIG. 1 is a plan view of an exemplary embodiment of an absorbent articleof the present invention and shows exemplary diaper 60 in its flat-out,uncontracted state, i.e., with all elastic induced contraction pulledout, with portions of the structure being cut away to more clearly showthe construction of the diaper, and with the portion of the diaper whichcontacts the wearer facing the viewer. FIG. 2 also shows an exemplarydiaper 60 in an exploded perspective view, with the portion thatcontacts the wearer on top. In these exemplary embodiments, the diaperis shown to have a periphery 57 defined by the outer edges of thediaper, with the longitudinal edges being designated 64 and the waistend edges being designated 16. The diaper additionally has a lateralcenterline which is designated 18 and a longitudinal centerline which isdesignated 17. The front waist region 12 and the back waist region 14extend, respectively, from the waist end edges 16 toward the lateralcenterline 18 a distance from about ¼ to about ⅓ the length of thediaper. The waist regions form those portions of the diaper which, whenworn, encircle the waist of the wearer. The crotch region 66 is thatportion of the diaper between the waist regions, and forms that portionof the diaper which, when worn, is positioned between the legs of thewearer and covers the lower torso of the wearer.

Another exemplary disposable diaper 60 embodiment of an absorbentarticle of the present invention is shown in partially segmentedperspective view in FIG. 3 and in a side view, partial cross-section inFIG. 4. The multi-piece absorbent core 10 including multiple absorbentcore components, such as the center section 50, the front panel 20, andthe back panel 30, is more fully illustrated and described below. Themulti-piece absorbent core is also described in the Weber et al. '602patent.

A multi-piece absorbent core having discrete components provides severalbenefits. First, the core exhibits desirable aesthetics and fit whenused in an absorbent article of the present invention due to the use ofdiscontinuous absorbent layers or panels of absorbent material. Forexample, the center section may include separate absorbent layers,allowing the center section to bend and buckle somewhat independentlyfrom adjacent absorbent layers and the front and rear panels and therebyprovide better fit and comfort in the crotch area than is typicallyachieved with one-piece absorbent cores.

A second advantage provided by a multi-piece absorbent core is theability to independently vary selected characteristics of the absorbentcore components and members. The characteristics that may be variedinclude the acquisition rates, distribution rates, storage capacitiesand rates, interfacial liquid transfer rates and efficiencies,thickness, functionality, and the shape or configuration of theabsorbent layers or panels. For example, in an exemplary embodiment ofan absorbent article of the present invention, three absorbent layersmay form the center section, with the absorbent layer closest to thebody of the wearer having relatively greater acquisition characteristicsthan the remaining two outer absorbent layers having relatively greateracquisition/distribution characteristics. In this configuration, bodilydischarges such as urine are quickly acquired by the body-side absorbentlayer serving as an acquisition member and then desorbed into theadjacent absorbent layers serving as acquisition/distribution membersfor distribution to the front and back panels, which preferably havegreater storage/redistribution characteristics.

A third benefit resulting from the use of a multi-piece absorbent corein an absorbent article of the present invention is the capability ofremoving and/or replacing components of the absorbent core to regeneratethe storage/redistribution capacity of the absorbent core. The provisionof access to the removable absorbent core components, for example, tothe back panel, allows the removal and/or replacement of those absorbentcore components. In this disclosure, all description of the back panels,their removal and replacement, and access to them for their removal andreplacement, is generally applicable to the front panels and vice versa,in various exemplary embodiments.

By replacing absorbent core components, particularly absorbent corecomponents that are primarily suited for storage/redistribution, the useof the absorbent article, such as the disposable diaper, may beprolonged while continuing to draw moisture away from the wearer's skin.As storage/redistribution absorbent core members in, e.g., the frontpanel and the back panel, become saturated, they may becomesubstantially less effective at absorbing moisture fromacquisition/distribution members in the center section. Consequently,the center section becomes more saturated, thereby hindering its abilityto absorb as much moisture away from the wearer's skin. However, once anabsorbent core component such as the back panel is replaced, theabsorbent suction of that absorbent core component is regenerated, andit once again becomes capable of absorbing moisture from theacquisition/distribution member of the center section. Therefore, thedisposable diaper may be worn longer, and regeneration of the absorbentcore may be made without removal of the diaper from the wearer.

It should be understood that the absorbent core described herein mayalso be useful for other absorbent articles such as incontinent briefs,incontinent pads, training pants, and the like, and that the presentinvention is not limited to the particular type or configuration ofdiaper shown in the drawing figures.

In the incorporated references, the entire absorbent core is typicallynon-removably disposed in the absorbent article. However, as describedthroughout this disclosure, specific components of the multi-pieceabsorbent core are removable and replaceable in absorbent articles ofthe present invention. For instance, the front panel 20 and/or the backpanel 30 may be removable and replaceable, while another component, suchas the center section 50, may be non-removably disposed in any of thepreviously known configurations and thereby be made non-removable fromthe absorbent article. Thus, absorbent articles of the present inventionhave both non-removable absorbent core components and absorbent corecomponents that are removable and replaceable.

As described in the incorporated references, components of the absorbentcore may be made non-removable from the chassis by being secured,attached, affixed, and/or sandwiched to or in the chassis. For example,as described in the Buell '003 patent, an absorbent core component canbe rendered immobile by, for example, bonding the backsheet and theabsorbent core component together, bonding the absorbent core componentto a topsheet and the topsheet to the backsheet, or tightly sandwichingthe absorbent core component between a topsheet and the backsheet. Also,as described in the Lawson '278 patent, an absorbent core component maybe superimposed on the backsheet and attached thereto by attachmentmeans such as those well known in the art. For example, the absorbentcore component may be secured to the backsheet by a uniform continuouslayer of adhesive, a patterned layer of adhesive, or an array ofseparate lines or spots of adhesive. In some exemplary embodiments, anabsorbent core component may be affixed in the crotch area of thechassis, as described in the DesMarais et al. '345 patent. Similarly, asdescribed in the Osborn '264 patent, an absorbent core component may beattached over the core's upper or lower major surfaces, respectively, toadjacent members such as the topsheet and the backsheet by any of themeans well known in the art, such as by spray-gluing or lines or spotsof adhesive. In fact, such attachment may facilitate the integrity andrecoverability of the absorbent materials while in use so as to maintainan optimum degree of absorbency.

In some exemplary embodiments of the present invention, a non-removableabsorbent core component, such as the center section, may be joined tothe chassis in a portion of the crotch region by affixing thenon-removable core component to the topsheet or the backsheet or to boththe topsheet and the backsheet. For example, the non-removable corecomponent may be joined at the crotch point to the chassis. The endportions of the non-removable core component, i.e., the portionsextending from the crotch region toward the front and back waistregions, may remain unattached to the chassis and thereby be free to“float” within the absorbent article. Alternatively, the front portionof the non-removable core component may be affixed to the chassis andonly the rear portion may be allowed to float. This floating coreconfiguration allows the unattached portion of the non-removable corecomponent to slide relative to the backsheet and or the topsheet whenthe absorbent article is applied to the wearer. The floating coreconfiguration also allows the unattached portion of the non-removablecore component to slide in response to the contraction of the chassiscaused by the elastics in the leg cuff regions of the absorbent article.Allowing a portion of the non-removable core component to slide relativeto the chassis may avoid the folding and wrinkling of the non-removablecore component that typically occurs in absorbent articles having theentire non-removable core component affixed to the distorted and/orcontracted chassis.

The Absorbent Article Chassis

As described throughout this disclosure, the liquid absorbent core canbe utilized in disposable absorbent products which are capable ofabsorbing significant quantities of bodily liquids, such as urine,perspiration, menses, and water in bodily wastes. These disposableabsorbent articles may be prepared in the form of disposable diapers,adult 15 incontinence briefs, training pants, and the like. Suchform-fitting articles will generally include a flexible substratefashioned into a chassis in the form of briefs or shorts when configuredfor wearing. A flexible substrate which forms the chassis of such aform-fitting article may include cloth or paper or other kinds ofnonwoven substrate or formed films and may be elasticized or otherwiseextensible. The chassis is the foundational element upon which theremainder of the structure of the article is built up or overlaid.

Because the designs of the chassis and the absorbent core areinterrelated, the absorbent core is included in the followingdescription in order to make the structural relationship between the twoclear. A more detailed description of the absorbent core, itself, may befound in the next section of this disclosure.

In the exemplary embodiments shown in FIG. 1 and FIG. 2, the diaper hasa substantially liquid impervious backsheet 62. On top of this backsheetis disposed an absorbent core 10 which may include one or more discreteabsorbent layers and may include a superabsorbent material in one ormore of the absorbent layers. On top of this absorbent core and joinedto the backsheet is a fluid pervious topsheet 61. The topsheet is theelement of the article that is placed next to the skin of the wearer.Additional structural features such as elastic members and fasteningmeans for securing the diaper in place upon a wearer, such as tape tabfasteners, may also be included, as will be described below.

In these exemplary embodiments, the topsheet and the backsheet arecoextensive and have length and width dimensions generally larger thanthose of the absorbent core. The topsheet is joined with andsuperimposed on the backsheet, thereby forming the chassis. While thetopsheet, the backsheet, and the absorbent core can be assembled in avariety of well known configurations, an exemplary diaper configurationis described generally in the Buell '003 patent. Alternative exemplaryconfigurations for disposable diapers herein are also disclosed in theAziz et al. '178 patent; the Lawson '278 patent; and the Foreman '025patent.

The backsheet is typically made of a material substantially imperviousto liquids and is preferably manufactured from a thin plastic film,although other flexible liquid impervious materials may also be used.The backsheet prevents the exudates absorbed and contained in theabsorbent core from wetting articles, such as bed sheets andundergarments, which contact the diaper. An exemplary backsheet may bemade of polyethylene film having a thickness from about 0.013 mm (0.5mil) to about 0.051 mm (2.0 mils), although other flexible liquidimpervious materials can be used. As used herein, the term “flexible”refers to materials which are compliant and which will readily conformto the general shape and contour of the wearer's body. A suitablepolyethylene film is manufactured by Monsanto Chemical Corporation andmarketed in the trade as Film No. 8020. The backsheet may be embossedand/or matte finished to provide a more clothlike appearance.

At least a portion of the backsheet may be subjected to mechanicalstretching to make it elongatable or drawable in order to provide a“zero strain” stretch laminate for, for example, forming elastic sidepanels. Suitable equipment and processes for such mechanical stretchingand for the formation of such a zero strain stretch laminate aredescribed in the Weber et al. '679 patent, the Buell et al. '793 patent,and the Weber et al. '897 patent.

Further, the backsheet may be “breathable”, permitting vapors to escapefrom the absorbent core while still preventing exudates from passingthrough the backsheet. It is contemplated that a backsheet that ishighly breathable but substantially impervious to liquid may bedesirable for certain absorbent articles. Such breathable compositematerials are described in greater detail in the Lim et al. '696 patent,in PCT Application No. WO 95/16746 in the name of Cardinal et al.,published on Jun. 22, 1995, and in the Curro '823 patent. Otherbreathable backsheets including nonwoven webs and apertured formed filmsare described in the Dobrin et al. '096 patent.

The size of the backsheet is dictated by the size of the absorbent coreand the exact diaper design selected. In an exemplary embodiment, thebacksheet has a modified hourglass-shape extending beyond the absorbentcore a minimum distance of at least about 1.3 centimeters to at leastabout 2.5 centimeters (about 0.5 to about 1.0 inch) around the entirediaper periphery.

The topsheet is compliant, soft feeling, and non-irritating to thewearer's skin. Further, at least a portion of the topsheet is liquidpervious permitting bodily liquids to readily penetrate through itsthickness. A suitable topsheet can be manufactured from a wide range ofmaterials such as woven and nonwoven materials; polymeric materials suchas apertured formed thermoplastic films, apertured plastic films, andhydroforned thermoplastic films; porous foams; reticulated foams;reticulated thermoplastic films; and thermoplastic scrims. Suitablewoven and nonwoven materials can include natural fibers, e.g., wood orcotton fibers, synthetic fibers, e.g., polymeric fibers such aspolyester, polypropylene, or polyethylene fibers, or a combination ofnatural and synthetic fibers. Preferably, the topsheet is made of ahydrophobic material to isolate the wearer's skin from liquids in theabsorbent core. Like the backsheet, at least a portion of the topsheetmay be subjected to mechanical stretching to make it elongatable ordrawable, in order to provide a “zero strain” stretch laminate for, forexample, forming elastic side panels.

A number of manufacturing techniques may be used to manufacture thetopsheet. For example, the topsheet can be formed of woven, nonwoven,spunbonded, carded, or like materials. In nonwoven topsheets, the fibersare typically bound together by a thermal binding procedure or by apolymeric binder such as polyacrylate. This sheet is substantiallyporous and permits a liquid to readily pass through it into theunderlying absorbent core. The topsheet material will preferably have noaffinity for holding aqueous bodily liquids in the area of contactbetween the topsheet and the wearer's skin. High loft nonwoven topsheetsand apertured formed film topsheets may be used in absorbent articles ofthe present invention. In some exemplary embodiments, apertured formedfilms may be preferred for the topsheet because they are pervious tobodily liquids and yet non-absorbent, and they have a reduced tendencyto allow liquids to pass through in a direction away from the absorbentcore and thereby rewet the wearer's skin. Thus, the surface of theformed film that is in contact with the body remains dry, therebyreducing bodily soiling and creating a more comfortable feel for thewearer. The body-facing surface of the formed film topsheet can behydrophilic, thereby helping bodily liquids transfer through thetopsheet faster and diminishing the likelihood that liquid will flow offthe topsheet rather than flowing into and being absorbed by theabsorbent core.

The topsheet may have an elasticated aperture adapted to permit feces topass through in a direction away from the wearer and be unattached in aportion of the crotch region and a portion of the rear of the chassis.The topsheet may be fully or partially elasticized or may beforeshortened to provide a void space between the topsheet and thenon-removable core component. Exemplary structures including elasticizedor foreshortened topsheets are described in more detail in the DesMaraiset al. '536 patent, in the Freeland '147 patent, in the Allen et al.'416 patent, and in the Freeland et al. '775 patent.

The topsheet and the backsheet are joined together in any suitablemanner. As used herein, the term “joined” encompasses configurationswherein the topsheet is directly joined to the backsheet by affixing thetopsheet directly to the backsheet, and configurations wherein thetopsheet is indirectly joined to the backsheet by affixing the topsheetto intermediate members which in turn are affixed to the backsheet. Inan exemplary embodiment, the topsheet and the backsheet are affixeddirectly to each other in the absorbent article's periphery byattachment means (not shown) such as an adhesive or any other attachmentmeans known in the art. For example, a uniform continuous layer ofadhesive, a patterned layer of adhesive, or an array of separate linesor spots of adhesive can be used to affix the topsheet to the backsheet.The topsheet may also be adhered to the absorbent core.

Furthermore, it is contemplated that a suitable absorbent core structurewithout a topsheet could be used to provide desirable results, such ascomfort and absorbency, as well as simplicity in manufacturing andmaterial cost savings. For example, the body-side surface of theabsorbent core could be made of liquid pervious, soft, compliant,non-irritating materials, thereby making a separate topsheetunnecessary. Such an absorbent core could be used in combination with abacksheet to provide the desired comfort and absorbency in an absorbentarticle.

Fastening means, such as tape tab fasteners 65, are typically disposedin the waistband region 63 of the diaper for holding the diaper on thewearer. The waistband region is generally considered to be that portionof the diaper extending from the waist end edge of the diaper to aboutthe laterally extending margin of the absorbent core. The tape tabfasteners depicted are representative, only, and the fastening means canbe any of those well known in the art, such as the fastening tapedisclosed in the Buell '594 patent, mechanical fasteners, hook and loopfasteners, zippers, buttons, and the like. These tape tab fasteners orother diaper fastening means are typically applied near the corners ofthe diaper.

The absorbent article may have an “open” chassis configuration, as shownin FIG. 1, in which the chassis is adapted to be fastened together aboutthe lower torso of a wearer by the fastening means. Suitablenon-limiting examples of an open chassis include the disposable diaperembodiments described in the Buell '092 patent and in the LaVon et al.'500 patent.

An open chassis may be at least partially pre-fastened prior to itsapplication onto the wearer. For example, articles capable of beingpre-fastened and then applied in a pull-on fashion include thosedescribed in the Kline et al. '097 patent and in the Kline et al. '098patent. In certain embodiments, the article may require a subsequentfastening step to adjust the size of, or the tension in, the waistcircumference of the article once the article has been applied over thewearer's lower torso. For example, articles having such two-stepfastening/tensioning systems include those described in the Magee et al.'866 patent.

Alternatively, the absorbent article may have a “closed” chassisconfiguration, such as that of a pull-on pant-type diaper or trainingpant, in which the chassis is adapted to be pulled on over the legs andlower torso of the wearer without any additional fastening steps.Suitable non-limiting examples of a closed system include the disposablediapers and training pants described in the Buell '234 patent and in theAshton '487 patent.

In both open and closed chassis configurations, it is desirable for theabsorbent article to have extensible side panels 210 and preferablyelastically extensible side panels to maximize the ease of insertion andremoval of the replaceable core component. Suitable non-limitingexamples of disposable absorbent articles having extensible side panelsare described in the Buell et al. '092 patent, in the Buell et al. '274patent, in the Roe et al. '145 patent, in the LaVon et al. '500 patent,in the Kline et al. '545 patent, and in the Robles et al. '306 patent.

Leg elastic members 69 may be disposed adjacent to the periphery of thediaper, preferably along each longitudinal edge 64 to form anelastically contractible leg cuff or side flap, so that the elasticmembers tend to draw and hold the diaper against the legs of the wearer.The leg elastic members may extend along a portion of the length of thediaper. Alternatively, the leg elastic members can extend the entirelength of the diaper, or any other length suitable to provide anelastically contractible line. The length of the leg elastic members isdictated by the diaper design.

A barrier leg cuff 240 including a barrier leg cuff elastic member 241may be disposed adjacent to each longitudinal edge 64 or between thelongitudinal edge and the longitudinal centerline 17 of the diaper.Suitable barrier leg cuff materials and structures are described in theLawson '278 patent, in the Young et al. '345 patent, in the DesMarais etal. '345 patent, in the Dyer et al., '207 patent, in the Foreman '025patent, and in the Aziz et al. '178 patent.

Additionally, waist elastic members 67 can be disposed adjacent toeither the front, the back, or both of the waistband regions of thediaper to provide a waistband as well as or rather than leg cuffs. Whilethe waistband can comprise a separate element affixed to the body of thedisposable diaper, it more often is an extension of other elements ofthe disposable diaper, such as the backsheet or the topsheet or both thebacksheet and the topsheet. Disposable diapers are normally constructedso as to have two waistbands: a front and a rear.

A suitable waistband is disclosed in the Kievit et al. '595 patent. Inone exemplary embodiment illustrated in the Kievit et al. '595 patent,elastic waist elements extend across essentially the entire lateralwidth of the disposable diaper. While this construction may be preferredin some exemplary embodiments, similar waistbands may be useful indesigns wherein the elastic waist elements extend across only a portionof the lateral width of the diaper. Preferably, the elastic waistelements extend across a major portion of the lateral width of thedisposable diaper.

The elastic members are secured to the diaper in an elasticallycontractible condition so that in a normally unrestrained configuration,the elastic members effectively contract or gather portions of thediaper. The elastic members can be secured in an elasticallycontractible condition in at least two ways. For example, the elasticmembers can be stretched and secured while the diaper is in anuncontracted condition. Alternatively, the diaper can be contracted, forexample, by pleating, and the elastic members can be secured andconnected to the diaper while the elastic members are in their unrelaxedor unstretched condition. A method and apparatus suitable formanufacturing a disposable diaper having elastically contractibleelastic members is described in the Buell '301 patent.

In use, an open chassis version of the diaper is applied to a wearer bypositioning one waistband region under the wearer's back, and drawingthe remainder of the diaper between the wearer's legs so that the otherwaistband region is positioned across the front of the wearer. Thetape-tab or other fasteners are then secured, preferably to outwardlyfacing areas of the diaper, as shown in FIG. 4, for example. As can beseen in FIG. 4, the chassis forms a waist opening 13 and leg openings 15when configured for wearing.

The Absorbent Core

In use, the disposable diapers or other absorbent articles of thepresent invention tend to more quickly and efficiently distribute andstore liquids and to remain dry due to the high absorbent capacity ofthe absorbent core components. Disposable diapers incorporating theabsorbent core components of the present invention can also be thinnerand more flexible.

FIG. 5 shows an exploded perspective view depicting the elements of anexemplary embodiment of a shaped absorbent core 10 such as may be usedin an absorbent article according to the present invention, for example,in a disposable diaper. FIG. 6 shows a top plan view of such a shapedabsorbent core 10.

As depicted in FIG. 5 and FIG. 6, the absorbent core 10 includes a frontpanel 20 and a back panel 30, both made of absorbent material,preferably material suitable for liquid storage/redistribution. Thefront panel has an outer front end 21, an inner front end 22, and a pairof sides 23. Similarly, the back panel has an outer back end 31, aninner back end 32, and a pair of sides 33. In this exemplary embodiment,the front and back panels, together with the center section 50,generally form an elongated hourglass shape suitable for use in adisposable diaper or similar absorbent article.

Since the center section 50 and the front panel 20 and the back panel 30are discrete absorbent core components, the center section 50 may benon-removable, while the front panel 20 or the back panel 30, or both,may be removable from the diaper 60. Thus, when the front panel 20 orthe back panel 30 becomes saturated with bodily discharges, such asurine, it can be removed and replaced with a fresh panel for continueduse of the absorbent article.

The center section may be generally rectilinear. The term “generallyrectilinear” refers to the center section having a generally constantwidth along its length. In general, however, the center section may havea varying width along its length. The center section may extend fromabout the outer front end 21 of the front panel, to about the outer backend 31 of the back panel, as shown in FIG. 6. In use, however, thecenter section need only be in capillary liquid communication with thefront and back panels, such as by overlapping in a layered relationship,and may not extend to the outer front end or the outer back end.

In an exemplary embodiment, the width 53 of the center section issuitable for comfortably fitting within the crotch area of the wearerwhen the absorbent core is incorporated into an absorbent article, suchas a disposable diaper. The length of the generally rectilinear centersection may be varied to provide a suitable fit for various wearersizes.

In a generally flat, unfolded state, the front panel and the back panelare disposed such that the inner front end 22 of the front panel isopposed to and spaced from the inner back end 32 of the back panel asshown in FIG. 5 and FIG. 6. The distance between the front and backpanels may be varied as necessary. In general, the distance willincrease as the crotch length increases with the size of the absorbentarticle. The front panel generally lies in the front waist region, withthe outer front end 21 being generally near the front waist end edge andthe inner front end 22 lying in the crotch region. Similarly, the backpanel lies in the back waist region, with the outer back end 31 beinggenerally near the back waist end edge and the inner back end 32 lyingin the crotch region. In some exemplary embodiments, the back panel 30is longer than the front panel 20. Such a configuration lends itself toa better fit when the absorbent core is used in a disposable diaper.

As shown in FIG. 2, FIG. 3, FIG. 5, and FIG. 6, the front panel 20 mayhave cut-out areas 40 at the intersection of the sides 23 and the innerfront end 22 and the back panel 30 may have cut-out areas 40 at theintersection of the sides 33 and the inner back end 32. The cut-outareas, or notched portions, join the sides and the inner ends such thatthe resulting widths of the inner ends 22 and 32 are narrower than thoseof the outer ends 21 and 31, respectively and, as shown in the figures,approach the width 53 of the center section, which is suitable forcomfortably fitting within the crotch area of the wearer when theabsorbent core is incorporated into an absorbent article, as statedabove. The term “notched” refers to a shape in which, instead of a sideand an end meeting generally at a right angle, some amount of materialis removed from the corner to produce an additional edge portion joiningthe side and the end. The additional edge portion of the cut-out areasmay be generally straight, but in an exemplary embodiment it isgenerally arcuate, as depicted in FIG. 6. It is also contemplated thatthe cut-out areas may have generally straight sides, with the limitingexample resulting in a back panel or a front panel being substantiallytrapezoidal in shape.

It is important for understanding the present invention to note that,unlike the front panel and the back panel of the absorbent core of thepresent invention, an absorbent core component that extends from onewaist region through the crotch region to the opposing waist region ofan absorbent article typically presents several disadvantages relativeto its potential use as a replaceable core component. Fundamentally, anysuch core component must both fit comfortably in the relatively narrowcrotch of the wearer and provide a useful amount of absorbent capacity,both in the crotch region and in the waist regions. The hourglass shapeof many absorbent cores in absorbent articles known in the artrepresents a compromise between the requirements of making the crotchportion of the core narrow enough to fit comfortably, yet wide enough toprovide sufficient absorbent capacity in the crotch region to acceptgushes of urine, and making the waist region portions of the core largeenough to provide sufficient overall absorbent capacity. The removal orthe insertion of such an absorbent core component extending through thecrotch region while the absorbent article is being worn would berelatively difficult and/or impractical, because either the removal orthe insertion would necessitate passing an entire relatively wide waistregion portion of the absorbent core component directly through therelatively narrow crotch of the wearer. Specifically, the removal wouldrequire either pulling one relatively wide waist region portion of thecore component through the wearer's relatively narrow crotch toward theopposing waist region without tearing or otherwise disassembling thecore component, or reaching into both the front and the back of thewaist opening to both push and pull the core component through thewearer's crotch. The insertion would require both forcing a relativelywide waist region portion of the core component through the wearer'srelatively narrow crotch, either by pushing it through the crotch or byboth pulling and pushing it through the crotch, and then spreading thatwaist region portion of the core component in order to dispose itproperly in the waist region of the absorbent article. It is clear thatthe performance of such a removal or, especially, of such an insertion,would be highly uncomfortable for the wearer and that the likelihood ofits successful completion, i.e., the likelihood of its completionwithout tearing or otherwise damaging the absorbent core component orthe chassis of the absorbent article, would be low.

It is also important to note that if, in an attempt to facilitate theremoval and/or the insertion of such an absorbent core componentextending through the crotch region, an oversized absorbent article isapplied to a wearer or an absorbent article is applied relativelyloosely onto the torso of a wearer, the likely results are theundesirable leakage of bodily liquids from the poorly fitted legopenings and the sagging or sliding of the absorbent article toward theknees of the wearer. The occurrence of either of these problems wouldclearly negate the very benefits of containment of bodily liquids thatthe absorbent article is intended to provide. Similarly, if an absorbentarticle is applied properly but then must be loosened in order tofacilitate the removal and/or the insertion of such an absorbent corecomponent, not only is the same unacceptable leakage likely to occur,but the proper fit of the absorbent article on the torso of the weareris likely to be difficult to restore. In addition, such loosening,manipulation of the absorbent core component through the wearer'scrotch, and restoration of the fit by tightening the absorbent article,is very likely to be annoying to the wearer and, therefore, difficultfor the caregiver to accomplish. Hence, the removable absorbent corecomponents and absorbent inserts known in the art that extend from onewaist region through the crotch region to the opposing waist region aretypically intended to be removed only when the absorbent article hasbeen opened and/or removed from the body of the wearer, rather thanwhile the absorbent article is being worn. In the few instances wheresuch a removable absorbent core component is asserted to be removablewhile the article is being worn, no assertion is made of the impracticalcontention that a like replacement core component can be inserted.

In particular, it is preferred that the front panel or the back panel ofthe absorbent core of the present invention extend from the respectivewaist region into the crotch region no farther than the crotch point ofthe absorbent article. Thus, the front panel and the back panel areparticularly well suited for use as replaceable core components. Becauseeach of these panels extends only from a waist region into the crotchregion, but not through the crotch region to the opposing waist region,it can be removed and replaced without the necessity of passing anyportion of the panel, the fingers or hand of the caregiver, or aninsertion tool through the wearer's crotch. Nevertheless, because theinner end of each of these panels can be shaped to fit comfortably intothe crotch area of the wearer's body, as described above, the inner endcan be optimally positioned for the absorption of liquid from the centersection, i.e., from the non-removable core component that extendsthrough the wearer's crotch and thus can serve to transport liquid fromthe front waist region to the back panel or from the back waist regionto the front panel.

The center section may include multiple layers of absorbent material,each having individual liquid acquisition, acquisition/distribution orstorage/redistribution characteristics, as well as individual shape,width, length and thickness characteristics. The number and placement ofabsorbent layers of the center section may be varied to achieve desiredcharacteristics such as thinness, softness, flexibility, or beneficialliquid acquisition, distribution, and storage rates. For example, thelayers of the center section need not extend from one waist regionthrough the crotch to the opposing waist region. In particular, thecenter section may include an absorbent layer extending from one waistregion into the crotch region, where it ends, and another absorbentlayer extending from the opposing waist region into and ending in thecrotch region. The number of absorbent layers of the front and backpanels may also be varied to achieve desired characteristics such asbeneficial liquid acquisition and distribution rates, as well ascapacity and storage rates, and wearer comfort. For example, in FIG. 3,the absorbent core is shown with the center section 50 and the front andback panels 20 and 30 each having a single absorbent layer. However, thecenter section has three absorbent layers in the exemplary embodimentsshown in FIG. 2 and FIG. 5, with two absorbent layers designated 51 andone absorbent layer designated 52. Also, the back panel is shown in FIG.12 as a core component made up of back panel absorbent layers 34, 35,and 36.

In the exemplary embodiment shown in cross section in FIG. 7 andcorresponding to the general top view of FIG. 6, one upper absorbentlayer 52 and one lower absorbent layer 51 are both placed over front andback panels 20 and 30, resulting in a thin, flexible absorbent core. Theterm “over” refers to the surface of the absorbent core of the inventioncorresponding to the wearer's body when used in an absorbent articlesuch as a disposable diaper, i.e., the body-facing surface. It is noted,however, that FIG. 7 is representative of only one exemplary embodimentand it may be beneficial to place the absorbent layers 51 or 52 underthe front and back panels 20 and 30. The term “under” refers to thesurface of the absorbent core of the invention corresponding to thegarment side when used in an absorbent article such as a catamenial pador disposable diaper, i.e., the garment-facing surface. It should alsobe understood that the term “upper” refers to the absorbent layer of theabsorbent core which is nearest to and faces the article topsheet;conversely, the term “lower” refers to the absorbent layer of theabsorbent core which is nearest to and faces the article backsheet.

Other arrangements of the absorbent layers of the center section and thefront and back panels are also possible. For example, FIG. 8 shows incross-section an additional exemplary embodiment corresponding to thegeneral top view of FIG. 6, in which two absorbent layers of front andback panels 20 and 30 are placed under the center section 50. As shownin the Weber et al. '602 patent and in FIG. 9, an alternative embodimentmay have a center section 50 having two absorbent layers 51, one placedover front and back panels 20 and 30, and one placed under the front andback panels, thereby sandwiching the front and back panels betweenabsorbent layers of the center section. As another example, as shown inthe Weber et al. '602 patent and in FIG. 10, the front and back panels20 and 30 may have two absorbent layers, with one absorbent layer placedover the center section 50 and one absorbent layer placed under thecenter section 50, thereby sandwiching the ends of the center sectionbetween absorbent layers of the front and back panels.

As shown in FIG. 7, the uppermost absorbent layer 52 is generally on theside corresponding to the body side of an absorbent article, such as adisposable diaper. Therefore, the uppermost absorbent layer 52 isgenerally in capillary liquid communication with the topsheet 61 of thedisposable diaper, thereby acting to quickly acquire and partitionbodily exudates away from the wearer's body to the generally moreabsorptive lower absorbent layers 51 and to the front and back panels 20and 30. Adhesive bonding of the uppermost absorbent layer 52 to thetopsheet 61 may enhance the capillary liquid communication by providinginterfacial bonding and preventing topsheet separation from impedingliquid flow.

The Absorbent Core Materials

The components or members of the absorbent core may include laminates orcombinations of several sheets or webs of the requisite types ofmaterials. In general, each absorbent core component or member may bemade of any absorbent material or combination of materials having enoughstructural integrity to be handled as a discrete unit.

For example, in order for a non-removable core component, such as thecenter section, to function properly in use, it is preferable tomaintain the structural integrity of the component in order to maintainits ability to transport liquid from the front of the absorbent articleto the rear of the absorbent article and/or from the crotch region ofthe absorbent article to the waist regions. If an absorbent layer of thenon-removable core component is torn or fractured, the liquid transportand capillary liquid communication with the replaceable core componentcan be interrupted. Therefore, it is preferred that, when dry, theabsorbent layer or layers of the non-removable core component have atensile strength to break of greater than about 200 grams force and,more preferably, greater than about 400 grams force and, mostpreferably, greater than about 1000 grams force. It is also preferredthat, when completely wetted, the absorbent layer or layers of thenon-removable core component have a tensile strength to break of greaterthan about 100 grams force and, more preferably, greater than about 200grams force and, most preferably, greater than about 400 grams force.The structural integrity can also be achieved by affixing a carrierlayer having the required tensile to break characteristics to thenon-removable core component or to the absorbent layer along its majorsurfaces or, alternatively, by wrapping the non-removable core componentor the absorbent layer in the carrier layer.

Typical materials known in the art may be used for the absorbent corecomponents and/or members, such as fibrous nonwoven materials, fibrousair-laid materials, fibrous wet-laid web materials, and combinations offibrous materials having absorbent gelling materials dispersed upon orwithin the fibrous structure. If necessary, such absorbent corecomponents or members may be formed into a packet having the fibrousmaterials substantially enveloped by a liquid pervious web that providesthe structural integrity for the removal and replacement into theabsorbent article. An exemplary form of a non-woven fibrous absorbentstructure that may be utilized in the present invention is constructedfrom hydrophilic chemically stiffened cellulosic fibers, as taught inthe Lash '728 patent and the Young et al. '345 patent, as well as in theSeger et al. '416 patent.

Absorbent materials for use as absorbent core components or members mayalso be foam-based. For example, a component of the absorbent core mayinclude a foam material in the form of a sheet or a plurality of foampieces or particles, which may be adhesively bonded together or whichmay simply be constrained into an unbonded aggregate held together by anoverwrapping of envelope tissue or by means of the topsheet andbacksheet of the absorbent article. Particularly suitable absorbentfoams for absorbent articles such as diapers have been made from HighInternal Phase Emulsions, hereafter referred to as “HIPE”. See, forexample, the DesMarais et al. '345 patent, the DesMarais et al. '224patent, and the Stone et al. '179 patent.

The absorbent core of the absorbent articles described herein can alsoinclude a combination of conventional elements or materials and one ormore foam absorbent structures. For example, the absorbent articles mayutilize an absorbent core which includes a combination, e.g., an airlaidmixture, of particles or pieces of the foam absorbent structures andconventional absorbent materials such as wood pulp or other cellulosicfibers and/or particles or fibers of polymeric gelling agents.

Besides acquiring bodily liquids rapidly, the absorbent acquisitionmember of the present invention should give up this liquid efficientlyto the liquid acquisition/distribution or storage/redistributionmembers. This liquid transfer function of the acquisition member is ofparticular importance because the acquisition member must havesufficient capillary suction to substantially drain the liquid from thetopsheet and yet not exhibit excessive liquid retention, which wouldmake it difficult for the underlying absorbent layer to desorb theacquisition member.

In particular, the liquid acquisition member should have a suitablecapillary desorption pressure relative to the absorption pressure ofother absorbent core members, especially those intended for liquidstorage. If the liquid acquisition member of the absorbent article holdsthe acquired liquid too tenaciously, this will inhibit the ability ofthese other members to partition liquid away and can cause theacquisition member to remain so heavily loaded with liquid that theabsorbent article is more susceptible to leaking.

This principle, according to which the relationship of the capillaryabsorption pressure of one absorbent element and the capillarydesorption pressure of another absorbent element defines the liquidflow, liquid transfer, and capillary liquid communicationcharacteristics of the absorbent article, is that of a capillarycascade. For example, the wearer-facing layer of the absorbent article,e.g., a topsheet, is liquid pervious and has particular capillaryabsorption and desorption pressures. The capillary desorption pressureof this topsheet is preferably less than the capillary absorptionpressure of the non-removable core component and, specifically, lessthan the capillary absorption pressure of the uppermost absorbent layerof the non-removable core component, with which the topsheet will be incontact. It is also preferred that the capillary absorption pressure ofan intermediate or lowermost absorbent layer of the non-removable corecomponent is greater than the capillary desorption pressure of thetopsheet. In addition, it is preferred that the absorption pressure of alower absorbent layer of the non-removable component be greater than thecapillary desorption pressure of the uppermost absorbent layer of thenon-removable core component. Furthermore, it is preferable that thecapillary absorption pressure of the storage/redistribution member ofthe replaceable core component be greater than the capillary desorptionpressure of the absorbent layer of the non-removable core component incontact with the replaceable core component.

In addition to having to overcome the capillary desorption pressure ofan adjacent absorbent structure, an absorbent layer must overcome thedifference in vertical height between a source of liquid and the portionof the absorbent layer to which it is desired to move the liquid bycapillary transport. The magnitude of this vertical head may be on theorder of 15 cm to 20 cm in some embodiments of the present invention, inwhich liquid is moved from the lower portion of the crotch region to theupper waist region of an absorbent article worn by a standing wearer, ismoved from the front portion to the back panel of an absorbent articleworn by a wearer lying in a face-down posture, or is moved from the backportion to the front panel of an absorbent article worn by a wearerlying in a face-up posture.

As an example of a suitable capillary cascade relationship, in someexemplary embodiments, it is preferred that the uppermost absorbentlayer of the non-removable core component have a capillary absorptionpressure of between 2 cm and 10 cm and a capillary desorption pressureof between 5 cm and 25 cm. A lower absorbent layer of this non-removablecore component preferably has a capillary absorption pressure of between10 cm and 40 cm and a capillary desorption pressure of between 20 cm and60 cm and is thereby capable of desorbing liquid from the uppermostabsorbent layer. For embodiments in which the non-removable corecomponent includes only a single absorbent layer of material or astratified structure, the capillary absorption pressure of thenon-removable core component is preferably between 2 cm and 40 cm andthe capillary desorption pressure is between 5 cm and 60 cm.

The liquid acquisition/distribution member may include materials similarto those used in the acquisition member, but preferably having moredistributive characteristics. Since discharged aqueous bodily liquid,e.g., urine, is frequently discharged in gushes, theacquisition/distribution member must be able to quickly acquire thisliquid and must also transport the liquid by wicking or anothermechanism from the point of initial liquid loading to other parts of theacquisition/distribution member for eventual desorption to the adjacentliquid storage/redistribution member. Thus, such materials preferablyhave a greater degree of distributive capacity than the acquisitionmember materials, such that bodily exudates may be efficientlytransported from the acquisition zone to the storage members of theabsorbent core.

In some embodiments, it may be desirable to have a “biased” absorbentcore structure, wherein a portion adjacent to one surface is capable ofrapidly acquiring a liquid with minimal dispersion, while a portionadjacent to an opposing surface is capable of rapidly dispersing aliquid with lesser acquisition capability. When oriented in an absorbentarticle such that the “acquisition side” is oriented toward the wearerand the “distribution side” is oriented away from the wearer, a “downand out” functionality is provided, whereby liquid is rapidly acquiredinto the absorbent core structure with minimal dispersion on itswearer-facing side and is rapidly distributed throughout the portion ofthe absorbent core structure on its garment-facing side. Thisfunctionality allows the maintenance of a clean and dry visible andtactile impression of the absorbent core structure, and hence theabsorbent article, while effectively utilizing the absorptive capacityof the regions of the absorbent article oriented away from the wearer.

In order to provide the above-described functionality in some exemplaryembodiments, compositions for the absorbent core may be selected suchthat the acquisition side of the absorbent layer is comparatively freeof small, high surface area fibers which provide good distributive andstorage characteristics but less than optimal acquisitioncharacteristics and such that the distributive side of the absorbentlayer has a comparatively higher proportion of such small, high surfacearea fibers so as to provide greater distribution characteristics. Insome embodiments, the acquisition area may have both a relatively loweraverage density and lower average basis weight per unit area than thedistribution area to establish the preferred capillarity force gradientbetween them. Also, in foam absorbent core structures, cell sizes andhole sizes are parameters that can impact a number of importantmechanical and performance features of the foams, including their fluidwicking properties and the capillary pressure that is developed withinthe foam structure, as described in the Stone '179 patent.

Optionally, a liquid pervious sheet, e.g., a tissue sheet, or a scrimlayer is positioned between the acquisition/distribution member and thestorage/redistribution member to maintain the physical integrity of theacquisition/distribution member during processing and/or use. Thisliquid pervious sheet can envelop all or part of theacquisition/distribution member, or simply be positioned as describedabove, without necessarily enveloping the acquisition/distributionmember. In embodiments in which the center section of the absorbent coreincludes the acquisition and acquisition/distribution members and isplaced over or under a replaceable absorbent core component or absorbentinsert including the storage/redistribution member, such as a backpanel, a single such liquid pervious sheet may suffice. Alternatively,in embodiments in which absorbent layers of the center section sandwichthe replaceable absorbent core component or absorbent insert, two ormore such liquid pervious sheets may be positioned to separate theabsorbent layers of the center section and the replaceable corecomponent. These multiple liquid pervious sheets may be described asforming a surface of or lining the openable chassis pocket formed by andbetween the sandwiching absorbent layers of the center section.Similarly, in embodiments in which absorbent layers of a replaceableabsorbent core component or absorbent insert sandwich an end of thecenter section, two or more such liquid pervious sheets may bepositioned to separate the absorbent layers of the center section andthe replaceable core component. In the latter embodiment, the multipleliquid pervious sheets may be described as forming a surface of orlining the two-part openable chassis pocket into which the replaceableabsorbent core component or absorbent insert is inserted and which isformed by and between the topsheet and the center section and by andbetween the center section and the backsheet, respectively.

An absorbent core suitable for use with the present invention includesat least one absorbent core component including a liquidstorage/redistribution member and may include two such components, e.g.,in the form of front and back panels. Each absorbent core componenthaving a liquid storage/redistribution member acts to store bodilyexudates away from the wearer's body, so as to leave the wearer with afeeling of dryness and to prevent leakage. The absorbent core componenthaving the liquid storage/redistribution member is maintained incapillary liquid communication with the acquisition and/oracquisition/distribution member(s), such that urine or other aqueousbodily liquid can be desorbed from the acquisition and/oracquisition/distribution member(s) and be absorbed by the liquidstorage/redistribution member.

The storage/redistribution member may include a member or members havingprimarily liquid storage characteristics. Such a storage member may havelimited transport and wicking capabilities but high storage or retentioncapacity, and rely upon a liquid distribution member to distributeincoming liquid over a larger area of the storage/redistribution member.

In order for a replaceable core component such as the back panel tofunction well within the context of the present invention, an absorbentlayer of the replaceable core component preferably has an absorptionpressure that is sufficient to desorb liquid from anacquisition/distribution member of a non-removable absorbent corecomponent such as the center section, i.e., the absorption pressure ofthe absorbent layer of the replaceable core component is preferablygreater than the desorption pressure of the acquisition/distributionmember. Therefore, the absorbent layer of the replaceable core componentpreferably has an absorption pressure of between 25 cm and 80 cm. Anexemplary material capable of providing absorption pressures within thespecified range is a collapsed polymeric foam material comprising ahydrophilic, flexible, nonionic polymeric foam structure ofinterconnected open cells, which foam material, upon contact with bodytemperature liquid, expands and absorbs the liquid. An importantparameter of these foams is their glass transition temperature. Theglass transition temperature represents the midpoint of the transitionbetween the glassy and rubbery states of the polymer. Foams that have ahigher glass transition temperature than the temperature of use can bevery strong but will also be very rigid and potentially prone tofracture. When such foams are collapsible, but have been stored in thecollapsed state for prolonged periods, they also typically take a longtime to recover to the expanded state when wetted with aqueous fluidscolder than the glass transition temperature of the polymer. Such a foammay have a capillary suction specific surface area per gram in the rangefrom about 0.7 to about 8 m²/g or, preferably, from about 1 to about 7m²/g, and most preferably from about 1.5 to about 6 m²/g. Such a foamwill preferably have a number average cell size of about 50 microns orless and typically in the range of from about 5 to about 50 microns.More preferably, the number average cell size will be in the range fromabout 5 to about 40 microns and, most preferably, from about 5 to about35 microns.

The absorbent articles of the present invention are preferablyconstructed such that when liquid is deposited in the article, theliquid is quickly absorbed and transported from the non-removable corecomponent to the replaceable core component. In order to minimize thebulk of the absorbent article and to maximize the benefits of skinhealth and dryness, it is preferable that the non-removable corecomponent have a liquid storage capacity that is low relative to thetotal capacity of the absorbent core, i.e., relative to the total of thesummed capacities of the non-removable and replaceable core components.Furthermore, it is desirable to remove the majority of the liquiddeposited in the article by removing the replaceable core component andreplacing it with a fresh dry component. Therefore, it is preferred thatthe liquid absorptive capacity of the replaceable core component besignificantly greater than the liquid absorptive capacity of thenon-removable core component. The liquid absorptive capacity of thereplaceable core component is preferably at least about 1.5 times asgreat as the liquid absorptive capacity of the non-removable corecomponent, more preferably at least about 2 times as great, and mostpreferably at least about 4 times as great as the liquid absorptivecapacity of the non-removable core component.

The replaceable core component may include an absorbent layer includingan acquisition material, which may be the same material as the uppermostabsorbent layer of the non-removable core component. This acquisitionmaterial may form a portion of the outer surface of the replaceable corecomponent or, alternatively, the acquisition material may be disposedunder another layer of liquid pervious material. The absorbent layer ofthe replaceable core component including the acquisition material may bedisposed in capillary liquid communication with the topsheet or incapillary liquid communication with a portion of the non-removable corecomponent.

In some embodiments, the replaceable core component may include anabsorbent layer including a distribution material, which may be the samematerial as that in an intermediate or a lower absorbent layer of thenon-removable core component. This distribution material may form aportion of the outer surface of the replaceable core component or,alternatively, the distribution material may be disposed under anotherlayer of liquid pervious material. The distribution material may bedisposed adjacent to either the wearer-facing surface of the replaceablecore component or the garment-facing surface of the replaceable corecomponent, or both. Furthermore, the distribution material may be incapillary liquid communication with the topsheet or in capillary liquidcommunication with a portion of the non-removable core component.

The replaceable core component may include multiple absorbent layers orpieces, including at least a liquid storage member and/or a liquidstorage/redistribution member. The replaceable core component may alsohave one or more layers forming a packet to partially or completelycontain the absorbent layer or layers. The packet layers may includeliquid pervious materials, liquid impervious materials, or combinationsthereof, and at least a portion of one of the packet layers forming theouter surface of the replaceable core component must have a liquidpervious region. In some embodiments, an outer surface of thereplaceable core component may be formed by an acquisition member, adistribution member, or an acquisition/distribution member disposed insuch a way as to contain the absorbent layer or layers in which theliquid storage member and/or the liquid storage/redistribution member isincluded. Also, in some embodiments, these additional absorbent membersmay be disposed between the packet layers forming the outer surface ofthe replaceable core component and the storage or storage/redistributionmember.

In summary, the absorbent core 10 includes a plurality of discretecomponents, each component having distinct liquid acquisition,acquisition/distribution, or storage/redistribution characteristics. Solong as each of the acquisition, acquisition/distribution, andstorage/redistribution members is in capillary liquid communication withan adjacent member or members, the absorbent core components may bepositioned relative to one another in a wide variety of configurations.There is no particular criticality with respect to the positionalrelationship of the acquisition/distribution member and the liquidstorage/redistribution member within the absorbent core so long as thesemembers are in effective capillary liquid communication with each otherand so long as each member is capable of effectively holding and/ortransporting the amount of aqueous bodily liquid that is expected to bedischarged into the absorbent article. It should be noted that thevarious structures of absorbent articles according to the presentinvention may or may not be generally planar in nature, and may beshaped or profiled in any desired configuration.

The Structure Allowing Removal and Replacement of Core Components

As shown in FIG. 2, FIG. 3, and FIG. 4, the backsheet 62 of someexemplary embodiments of an absorbent article of the present inventionmay have an aperture 44 in the general proximity of the front panel 20or rear panel 30, or both.

As shown in FIG. 4, the aperture 44 provides access into what may bedescribed as an openable chassis pocket 5, with a removable absorbentcore component, for example, the back panel 30, being disposed insidethe openable chassis pocket when the diaper is being worn, and beingremovable from and replaceable into the openable chassis pocket throughthe aperture. For example, after the removal of a saturated back panel,a fresh, unused absorbent core component may be reinserted through theaperture. A flap 42 may be provided to cover the aperture. The materialused for the backsheet may be used for the flap as well. When thedisposable diaper is being worn, the flap may be secured over theaperture by suitable fasteners 43, such as VELCRO strips or adhesivestrips (not shown). For example, FIG. 4 shows the flap in the closedposition over the aperture adjacent to the front panel 20 (shown in FIG.3). More preferably, the flap is sealed with releasable adhesive,thereby providing for liquid impermeability when closed, but allowingfor multiple openings and closings.

In the exemplary embodiment shown in FIG. 3 and FIG. 4, the back panel30 is disposed under the center section, as in the description of FIG.7, above, and the openable chassis pocket 5 is formed by and between thecenter section 50 and the backsheet 62. In other exemplary embodiments,in which the center section and the removable core component orcomponents are arranged differently, the openable chassis pocket may beformed by and between different components and layers. For example, inan embodiment in which the back panel is disposed above the centersection, the openable chassis pocket may be formed by and between atopsheet and the center section. Similarly, when the back panel issandwiched between absorbent layers of the center section, as in FIG. 9,the openable chassis pocket may be formed by and between the sandwichingabsorbent layers of the center section. Also, when the center section issandwiched between absorbent layers of the back panel, as in FIG. 10,the openable chassis pocket may be formed in two parts, by and betweenthe topsheet and the center section and by and between the centersection and the backsheet, respectively.

In general, the front panel, the back panel, and the correspondingapertures and flaps are substantially similar, but need not be. In analternative exemplary embodiment, it may be desired to include only oneaperture and flap, for example, for access to the back panel, withoutproviding a similar aperture for access to the front panel.

Alternatively, as shown in FIG. 11 and FIG. 12, a backsheet pocket sheet45 may be affixed on the garment-facing surface of the backsheetadjacent to the aperture 44 to form an openable chassis pocket 5 betweenthe backsheet pocket sheet and the backsheet. In these embodiments, aremovable and replaceable core component, such as back panel 30, may bedisposed outside, relative to the aperture, and a core component thatremains in the absorbent article, i.e., a non-removable core component,such as center section 50, may be disposed inside, relative to theaperture, such that the aperture allows capillary liquid communicationbetween the replaceable core component and the non-removable corecomponent.

The openable chassis pocket 5 formed by the backsheet pocket sheet 45may have its openable end 41 longitudinally nearest the adjacent waistend edge. The openable chassis pocket may be reclosable and may beresealable, and is preferably positioned so that the back panel is urgedinto capillary liquid communication with the center section. Thebacksheet pocket sheet is preferably resilient and pliable, and forms asubstantially liquid impervious barrier over the aperture, functionallybecoming an extension of the backsheet when the openable chassis pocketis closed.

The back panel is shown in FIG. 12 as a core component made up ofindividual back panel absorbent layers 34, 35, and 36. In such anembodiment, as one back panel absorbent layer, e.g., the uppermost backpanel absorbent layer 34, becomes saturated with bodily discharge it maybe removed, thereby exposing an adjacent prepositioned back panelabsorbent layer, e.g., the adjacent back panel absorbent layer 35.

FIG. 13 shows an exemplary embodiment of the arrangement of the backpanel 30, again showing representative back panel absorbent layers 34,35, and 36 in a layered relationship adjacent to the aperture 44 and incapillary liquid communication with the center section 50. Removal ofthe back panel absorbent layers through the openable end 41 of theopenable chassis pocket 5 may be facilitated by the use of pull tabs 46,which may be of any type known in the art, such as a strip of plasticfilm adhered to each back panel absorbent layer.

Additionally, the back panel absorbent layers may be separated from oneanother by a liquid impervious blocking layer 47 so that adjacent backpanel absorbent layers are not in capillary liquid communication witheach other. The blocking layer 47 may be any liquid impervious polymerfilm, such as film suitable for use as a liquid impervious backsheet. Asone back panel absorbent layer becomes saturated by absorption of liquidfrom the center section 50, it may be removed, thereby exposing asubstantially dry, fresh adjacent back panel absorbent layer foradditional absorption from the center section 50. In this manner, theabsorbent article may be refreshed or regenerated for a prolonged periodof time without the necessity of its removal from the wearer.

FIG. 14 shows an exemplary arrangement of the back panel absorbentlayers 35 and 36 in a layered relationship with the liquid imperviousblocking layer 47 disposed to form a liquid impervious layer betweenthem. A portion of the blocking layer is preferably affixed, for exampleat an attachment point 48, to the back panel absorbent layer beingremoved. As this back panel absorbent layer 35 is removed, the blockinglayer 47 is removed as well, thereby leaving the adjacent back panelabsorbent layer 36 in position to be urged into capillary liquidcommunication with the center section 50.

An alternative exemplary embodiment of the back panel 30 of an absorbentarticle of the present invention is shown in cross-section in FIG. 15,in which a back panel envelope 49 is shown in position to be attached tothe backsheet 62. The back panel envelope is shown as containing asingle back panel absorbent layer 34 enveloped between a substantiallyliquid impervious layer 54 and a substantially liquid pervious layer 55,and may be releasably affixed, for example, by a suitable releasableadhesive 39 known in the art, adjacent to the perimeter 38 of theaperture 44. When such a releasably affixed back panel envelope becomessaturated due to the absorption of liquid from the center section 50, itmay be removed and replaced with a fresh, dry back panel envelope 49.

In another alternative exemplary embodiment of an absorbent article ofthe present invention shown in cross-section in FIG. 16, the openableend 41 of the openable chassis pocket 5 may be formed along apredetermined area of the periphery 57, such as along the waist end edge16, either in the front, in the back, or both, where the topsheet 61 andthe backsheet 62 are separable to provide access to the removableabsorbent core component, e.g., the back panel absorbent layers 34 and35. The openable end formed by the separation of the topsheet and thebacksheet allows the removal and replacement of the removable absorbentcore components and may be resealable to provide a substantial degree ofliquid impermeability when closed. The openable end may be maderesealable, for example, with a suitable releasable and resealableadhesive 56 known in the art.

As can be seen in FIG. 13 and in FIG. 16, the openable chassis pocket 5generally has an outer end 27 and an inner end 28 corresponding to theouter end 31 and the inner end 32, respectively, of the back panel 30.In the exemplary embodiments shown in FIG. 13 and FIG. 16, the outer end27 of the openable chassis pocket coincides with its openable end 41.The inner end of the openable chassis pocket may be formed in severalways. For example, as shown in FIG. 13, the inner end may be formed atthe area of attachment of the backsheet pocket sheet 45 to thebacksheet. As described above, the backsheet, the topsheet, and thenon-removable absorbent core component may be secured, attached, oraffixed to each other in a variety of configurations. Thus, as anotherexample of the formation of the inner end of the openable chassispocket, an area of attachment of the non-removable absorbent corecomponent to the chassis, e.g., to the backsheet, the topsheet, or both,in the crotch region may form the inner end of the openable chassispocket.

In alternative embodiments, as shown in FIG. 17 and FIG. 18, a topsheetpocket sheet 202 may be affixed on the wearer-facing surface of thetopsheet 61 to form an openable chassis pocket 5 between the topsheetpocket sheet and the topsheet. The openable chassis pocket 5 formed bythe topsheet pocket sheet 202 may have its openable end 41 adjacent tothe nearest waist end edge 16. The openable chassis pocket may bereclosable and may be resealable, and is preferably positioned so thatan inserted back panel is urged into capillary liquid communication withthe center section. The topsheet pocket sheet is preferably resilient,pliable, and liquid pervious and may be formed of the same material asthe topsheet.

As is also shown in FIG. 17 and in FIG. 18, in some exemplaryembodiments having such an openable chassis pocket 5 formed by atopsheet pocket sheet 202, the topsheet 61 may have a topsheet aperture200 allowing face-to-face contact and capillary liquid communicationbetween a replaceable absorbent core component disposed in the openablechassis pocket, such as the back panel 30, and a non-removable absorbentcore component, such as the center section 50, disposed adjacent to anopposing surface of the topsheet. Such a topsheet aperture may have anarea of approximately 1 cm² or greater, and a smaller of its length andwidth dimensions may be approximately 5 mm or greater. Such a topsheetaperture may have a generally rectangular shape, a generally circularshape, or any other geometric shape having a ratio of smallest dimensionto greatest dimension of from 1:1 to approximately 1:100, including allintermediate ratios. In some exemplary embodiments, such a topsheetaperture may be covered with a layer of a permanently hydrophilicfibrous material. This topsheet aperture covering layer 201 may beformed of fibers that are naturally hydrophilic or of fibers that havebeen treated to make them permanently hydrophilic in the sheetstructure. Alternatively, the topsheet aperture may be covered with amesh having openings sufficiently large to allow the direct face-to-facecontact of the absorbent layers disposed on either side of the topsheet.Suitable non-limiting examples of materials that can be used to coverthe topsheet aperture include a permanently hydrophilic non-wovenavailable from SciMAT Limited of Swindon, U.K. under product code900/20, a mesh material such as a 100% nylon netting available fromWYLA, Inc. of New York, N.Y., U.S.A. under product designation RT80, anda tissue such as a cellulose tissue available from Georgia-PacificCorporation of Atlanta; Ga., U.S.A. under the designation of 65588.Another suitable material for use as the topsheet aperture coveringlayer comprises a bonded structure of curly cellulosic fibers, which mayalso include high surface area fibers as described herein.

As described in the chassis description, an elastic waistband 67 may bedisposed in the waistband region 63 between the waist end edge 16 andthe adjacent end of the absorbent core, as shown in FIG. 1 and in FIG.2. When such an elastic waistband is disposed adjacent to an openingformed by the separation of the topsheet and the backsheet along a waistend edge, the waistband may serve to make the opening elasticallyopenable and self-closing. For example, such an elastic waistband,formed as either a separate element affixed to the backsheet or as anextension of the backsheet in the waistband region, may exert acontractive force tending to draw the waist end edge of the backsheet atthe periphery toward the topsheet, thus tending to close the openableend of the openable chassis pocket when it is released.

As another example, an elastic waistband, formed as either a separateelement affixed to the topsheet or as an extension of the topsheet inthe waistband region, may exert a contractive force tending to hold thewaist end edge of the topsheet against the body of the wearer at alltimes, including when the waist end edge of the backsheet is pulled awayfrom the topsheet to form the opening and thereby gain access into theopenable chassis pocket. In addition, as described above in the chassisdescription, a flexible substrate forming the chassis, such as thebacksheet and the topsheet, may be elasticized or otherwise extensible.Thus, the superposed or layered portions of both the topsheet and thebacksheet in the openable area along the waist end edge may beelastically contractible, either by means of a waistband or otherwise.In such an embodiment, when the backsheet is pulled away for access intothe openable chassis pocket, the waist end edge of the topsheet may beheld elastically against the body of the wearer, thereby facilitatingthe access, and the opening may also be self-closing by means of theelastic contraction of the waist end edge of the backsheet when it isreleased.

In some exemplary embodiments, two elastically extensible waistbands maybe disposed in a layered configuration in a waist region of the chassisand may be separable for access into the openable chassis pocket formedbetween the topsheet and the backsheet, as shown in FIG. 19 and in FIG.20. In such an embodiment, a first extensible waistband 216 may bedisposed on the wearer-facing surface of, and attached to, thewearer-facing layer of the chassis formed by, for example, the topsheet61, the side panels 210, and/or the barrier leg cuffs 240, when theseelements are present. A second extensible waistband 217 may be attachedto the garment-facing layer of the chassis formed by, for example, thebacksheet 62. The first extensible waistband may have an extensibleportion 218 and a non-extensible portion 219 and may also have a freeportion 220 that is not attached to the wearer-facing layer of thechassis, i.e., that is free to move independently of the wearer-facinglayer of the chassis. The extensible portion 218 may be attached to thewearer-facing layer of the chassis by intermittent bonds 222, such asthose described in the Kievit et al. '595 patent. The first extensiblewaistband may have two laterally opposing ends 221 joined to thechassis. For a closed configuration, such as the pull-on style pantshown in FIG. 18, the opposing ends 221 are preferably joined to thechassis at or near the laterally opposed side seams 8. For an openconfiguration, such as the taped diaper shown in FIG. 17 or anotherchassis having laterally opposed side fasteners, the opposing ends 221may be attached to the wearer-facing layer at or near the laterallyopposed side fasteners, such as tape tab fasteners 65.

In such an embodiment, as can be seen in FIG. 20, this layered dualextensible waistband structure forms three openings when the secondextensible waistband and the garment-facing layer of the chassis areseparated from the first extensible waistband and the wearer-facinglayer of the chassis for access into the openable chassis pocket. Eachof two laterally opposed substantially triangular openings 223 is formedby the non-extensible portion 219 of the first extensible waistband 216,the adjacent side panel 210, and the adjacent connecting leg of thetriangle formed by the topsheet 61 and/or the barrier leg cuff 240.Between these triangular openings 223, a quadrangular opening 224 isformed by the topsheet 61, the second extensible waistband 217 and theadjacent portion of the backsheet 62 on which it is disposed, and thelaterally opposed connecting legs of the trapezoid formed by thetopsheet 61 and/or the laterally opposed barrier leg cuffs 240. Thecentrally located quadrangular opening 224 forms the openable end 41 ofthe openable chassis pocket 5, which is formed and bounded by the samefour elements as the quadrangular opening. In particular embodiments,such as that shown in FIG. 20, the quadrangular opening may have atrapezoidal shape, while in other embodiments, it may have asubstantially rectangular shape.

By forming these three openings when separated, this layered dualextensible waistband structure provides several advantages. For example,this waistband structure allows the first extensible waistband and thewearer-facing layer of the chassis to remain in contact with the body ofthe wearer at all times, including when the second extensible waistbandand the garment-facing layer of the chassis are separated from the firstextensible waistband and the wearer-facing layer of the chassis foraccess into the openable chassis pocket. By remaining in contact withthe body of the wearer, the first extensible waistband and thewearer-facing layer of the chassis can continue to perform theirintended function of helping to support the absorbent article andprevent its slippage downward on the torso of a standing wearer, evenduring the removal and replacement of the replaceable core component.Also, the centrally located quadrangular opening provides a readilyvisible “target” for the insertion of a replacement core component, aswell as a structurally bounded channel allowing the insertion of thereplacement core component only when it is substantially properlylaterally aligned with respect to the chassis.

In an alternative embodiment, as shown in FIG. 21 and FIG. 22, a firstextensible waistband 216 may be sandwiched between and attached to thewearer-facing layer and the garment-facing layer and a second extensiblewaistband 217 attached to or forming an extension of only thegarment-facing layer may be disposed adjacent to the first extensiblewaistband in a position farther from the adjacent waist end edge 16,i.e., toward the crotch region 66, relative to the first extensiblewaistband. The garment-facing layer, e.g., the backsheet 62, in such anembodiment may include an aperture 44 between the two extensiblewaistbands providing access into the openable chassis pocket 5 formedbetween the wearer-facing layer and the garment-facing layer when thesecond extensible waistband 217 is separated from the first extensiblewaistband 216 as shown in FIG. 22. Preferably, at least the secondextensible waistband is elastically extensible. In some embodiments, theportion of the garment-facing layer surrounding the second extensiblewaistband may also be extensible.

In an alternative embodiment shown in FIG. 23 and FIG. 24, an extensiblewaistband 215 may include a first portion 215 a sandwiched between andattached to the wearer-facing layer and the garment-facing layer in aportion of the waistband region adjacent to the waist end edge 16 and asecond portion 215 b attached to only the garment-facing layer anddisposed farther from the adjacent waist end edge, i.e., toward thecrotch region 66, relative to the first portion of the extensiblewaistband. The extensible waistband and the garment-facing layer, e.g.,the backsheet 62, in such an embodiment may each include an aperture 44between the two portions of the extensible waistband providing accessinto the openable chassis pocket 5 formed between the wearer-facinglayer and the garment-facing layer when the second portion 215 b isseparated from the first portion 215 a as shown in FIG. 24. Preferably,the extensible waistband is elastically extensible. In some embodiments,the portion of the garment-facing layer surrounding the extensiblewaistband may also be extensible.

In another alternative embodiment shown in FIG. 25 and FIG. 26, a firstextensible waistband 216 may be attached to the wearer-facing layer anda second extensible waistband 217 attached to or forming an extension ofthe garment-facing layer may be disposed adjacent to the firstextensible waistband in a position closer to the adjacent waist end edge16, i.e., farther from the crotch region 66, relative to the firstextensible waistband. The wearer-facing layer and the garment-facinglayer may be separable in the waistband region 63, providing access intothe openable chassis pocket 5 formed between the wearer-facing layer andthe garment-facing layer when the second extensible waistband and thegarment-facing layer of the chassis are separated from the firstextensible waistband and the wearer-facing layer of the chassis.Preferably, at least the second extensible waistband is elasticallyextensible. In some embodiments, the portion of the garment-facing layersurrounding the second extensible waistband may also be extensible.

As shown in FIG. 27, a portion of the non-removable core component, suchas the uppermost absorbent layer 52 of the center section, may bedisposed between a liquid pervious wearer-facing layer of the chassis,such as the topsheet 61, and another liquid pervious layer 205 of thechassis. One or both of the liquid pervious layers may form a portion ofthe openable chassis pocket 5 adapted to receive the replaceableabsorbent core component, e.g., back panel 30. Preferably, anacquisition member, a distribution member, or anacquisition/distribution member of the non-removable core component isdisposed between the liquid pervious layers. In some embodiments, atleast one of the liquid pervious layers may be disposed between twomembers of the non-removable core component.

Alternatively, a portion of the non-removable core component, such asthe lowermost absorbent layer 51 of the center section shown in FIG. 27,may be disposed between a liquid pervious layer 205 of the chassis and aliquid impervious layer of the chassis, such as the backsheet 62. One orboth of the liquid pervious layer and the liquid impervious layer mayform a portion of the openable chassis pocket 5 adapted to receive thereplaceable absorbent core component, e.g., back panel 30. Preferably, adistribution or acquisition/distribution member of the non-removablecore component is disposed between the liquid pervious and the liquidimpervious layers. In some embodiments, the liquid pervious layer may bedisposed between two members of the non-removable core component.

In order to provide additional space within the openable chassis pocket,the surfaces forming the openable chassis pocket, e.g., the topsheet,the backsheet, the barrier leg cuffs, etc., may be formed fromextensible materials, preferably elastically extensible materials, topermit the expansion of the pocket. These materials are preferablyextensible in at least in the lateral direction and preferably in boththe lateral and longitudinal directions. This expansibility of theopenable chassis pocket may facilitate the removal and/or the insertionof a replaceable core component and may also be useful in embodiments inwhich the replaceable core component includes an absorbent layer thatexpands as it absorbs liquid.

In some exemplary embodiments, the openable chassis pocket and thereplaceable core component may be “keyed” to each other, so as toprevent the insertion of the replaceable core component in anyorientation other than a predetermined orientation contemplated in thedesign of the replaceable core component. Thus, the openable chassispocket may be shaped and the replaceable core component may becorrespondingly shaped to fit within the shaped openable chassis pocket.

For example, in some embodiments as shown in FIG. 28, the openablechassis pocket 5 may include a separator 225 that bifurcates orpartitions the pocket into at least two connected branches forming theshaped openable chassis pocket. The separator may be formed by an areaof joining of the topsheet and the backsheet or by an area of joining ofthe topsheet or the backsheet, or both, to the non-removable corecomponent, thereby bifurcating or partitioning the openable chassispocket. In embodiments having such a bifurcated openable chassis pocket,the replaceable core component, e.g., back panel 30, may include acooperative structure 226 that permits the insertion of its inner end 32beyond the outer end 228 of the separator, i.e., to a point farther fromthe waist end edge than the outer end of the separator. Such acooperative structure may include a slit, a slot, or a groove formed inthe replaceable core component for receiving and/or bypassing theseparator. The separator in the openable chassis pocket may be formedalong the longitudinal centerline 17 of the chassis and the cooperativestructure in the replaceable core component may be formed along thelongitudinal centerline 25 of the replaceable core component or,alternatively, either the separator or the cooperative structure, orboth, may be offset from the respective longitudinal centerline. Eitherthe symmetric or the offset configuration may serve to ensure that thereplaceable core component is inserted in the intended end-to-endorientation, i.e., with its inner end in the crotch region and its outerend in the waist region. Either configuration may also serve to ensurethat the replaceable core component is inserted in a predeterminedlateral position, is inserted with its liquid pervious surface region ina predetermined longitudinal and/or lateral position, and so on. Inaddition, an offset configuration may be especially useful because, inorder to fit into the asymmetrically bifurcated openable chassis pocket,the replaceable core component must be inserted in both the intendedend-to-end orientation and the intended orientation of its predeterminedwearer-facing and garment-facing surfaces.

It is noted that more than one shaping element, such as more than oneseparator, as well as shaping elements other than a separator, areenvisioned. Exemplary shaping elements may include a slot into which acorresponding “key” fits in only a predetermined orientation, one ormore holes or depressions into which one or more corresponding pins,bosses, or protuberances fits in only a predetermined orientation, apartition within the openable chassis pocket that requires thereplaceable core component to be partially inserted and then rotatedand/or translated in order for the insertion to be completed, andsimilar configurations.

In embodiments in which the openable chassis pocket is divided intoseveral separate connected branches or into non-interconnected sections,i.e., divided effectively into separate openable chassis pockets, acorresponding number of replaceable core components may be placed intothe sections of the openable chassis pocket in a side-by-side lateralrelationship. For example, in some embodiments as shown in FIG. 28, apair of front panels 20 may be inserted into a bifurcated openablechassis pocket.

In some embodiments, the openable chassis pocket may extend from a waistregion into the crotch region as far as the crotch point. In particular,it is preferred that the openable chassis pocket extend from therespective waist region into the crotch region no farther than thecrotch point of the absorbent article, so as to thereby limit the depthof insertion of a replaceable core component to no farther than thecrotch point. The “crotch point” of an absorbent article and of theabsorbent article's absorbent core is determined by placing the articleon a wearer of the physical size for which the absorbent article isdesigned and who is in a fully upright standing position with his or herfeet a shoulder width apart and then placing an extensible filament 256around the legs 255 in a figure eight configuration as shown in FIG. 29.The point in the absorbent article and the absorbent core correspondingto the point of intersection 257 of the filament is considered to be thecrotch point of the absorbent article and of the absorbent core. It isunderstood that the crotch point is determined by placing an absorbentarticle in the intended manner on a standing wearer of the correct sizefor the article and determining where the crossed filament would contactthe absorbent article and/or the absorbent core.

The Replaceable Absorbent Core Component

In order for the absorbent layer of the replaceable core component to bein capillary liquid communication with the non-removable core component,at least a portion of one major surface of the replaceable corecomponent must be pervious to liquid. This pervious portion of the majorsurface may be described as forming a permeable liquid transfer region246. In exemplary embodiments, at least about 20% of the area of thismajor surface is liquid pervious. Preferably, at least about 50%, andmore preferably, at least about 80%, of this major surface may be liquidpervious. The permeable liquid transfer region may be covered by aliquid pervious sheet 247. Also, the replaceable core component may havepermeable liquid transfer regions in both of its major surfaces. Forexample, in the exemplary embodiment shown in FIG. 30 and FIG. 31, theback panel 30 has the permeable liquid transfer region 246 a in itsupper major surface formed by the upper packet layer 250a and thepermeable liquid transfer region 246 b in its lower major surface formedby the lower packet layer 250 b.

Except for the permeable liquid transfer region or regions, the majorsurfaces of the replaceable core component may be liquid impervious. Inparticular, it may be desirable for the outer end segment or at leastthe area of the pull tab at the outer end to be liquid impervious inorder to prevent the escape or the leakage of liquid from this portionof the replaceable core component. The prevention of leakage from thisarea may enable a caregiver to avoid contact during the removal of aused replaceable core component with the liquid contained in it. Aliquid impervious region may be formed by a liquid impervious layerdisposed between the absorbent layer of the replaceable core componentand the layer forming the surface, such as by the liquid imperviouslayer 253 disposed between the absorbent layer 34 of the back panel 30and the packet layer 250 shown in FIG. 27. Alternatively, the liquidimpervious region may be formed by a liquid impervious layer forming themajor surface or by the treatment of an otherwise liquid pervious layerto render it liquid impervious in the desired region. For example, inthe embodiment shown in FIG. 31, the portions of the packet layers 250between the permeable liquid transfer regions 246 and the outer end 31of the back panel 30 may either include a liquid impervious sheetmaterial or be treated to become liquid impervious.

The replaceable core component, e.g., the back panel 30 shown in FIG.32, has an inner end 32 and an outer end 31 and may be dividedlongitudinally for descriptive purposes into successive first, second,third, and fourth segments defined by respective quarters of its length.The replaceable core component may have two major surfaces havingsubstantially equal areas and, for descriptive purposes, the area ofeach of the four longitudinal segments may be expressed as the area ofthe portion of one of the major surfaces falling within the segment.When so divided, the first segment 111, which is also referred to hereinas the inner end segment, includes the inner end and may have an arealess than an area of any one of the second, third, and fourth segments.For example, the inner end of the replaceable core component may have asmaller width 115 than the width 116 of the second segment 112 and mayhave converging sides 117, i.e., the inner end segment may converginglytaper toward the inner end. The fourth segment 114, which is alsoreferred to herein as the outer end segment, includes the outer end andmay have an area less than the area of at least one of the secondsegment or the third segment 113. The areas of the second and thirdsegments may be substantially equal or the second segment may have anarea less than that of the third segment. In some embodiments, the foursegments may have the following areas. The first segment may have anarea of between 10 cm² and 110 cm² or, preferably, between 30 cm² and 70cm². The second segment may have an area of between 10 cm² and 110 cm²or, preferably, between 30 cm² and 100 cm². The fourth segment may havean area of between 10 cm² and 110 cm² or, preferably, between 30 cm² and100 cm². The third segment may have an area of between 10 cm² and 110cm² or, preferably, between 30 cm² and 100 cm². Based on these areas,the overall surface area of the replaceable core component may bebetween 40 cm² and 440 cm² or, preferably, between 120 cm² and 370 cm².

Similarly, the absorbent structure of the replaceable core component,e.g., an absorbent layer 34 of back panel 30, has an inner end 238 andan outer end 239 and may be divided longitudinally for descriptivepurposes into four successive segments 231, 232, 233, and 234 from itsinner end to its outer end, corresponding to the four segments of thereplaceable core component as a whole. Like the replaceable corecomponent, the absorbent structure may have two major surfaces havingsubstantially equal areas and, for descriptive purposes, the area ofeach of the four longitudinal segments of the absorbent structure may beexpressed as the area of the portion of one of the major surfacesfalling within the segment. In some embodiments, an absorbent layer mayextend from the first segment 111 of the replaceable core component tothe fourth segment 114 of the replaceable core component, as shown inFIG. 33. In other embodiments, the absorbent layer may extend only fromthe first segment 111 to the second segment 112 or to the third segment113 of the replaceable core component, as shown in FIG. 34. The firstabsorbent layer segment 231, or inner end segment of the absorbentlayer, includes the inner end of the absorbent layer and may have anarea less than an area of any one of the other segments of the absorbentlayer. For example, the inner end of the absorbent layer may have awidth smaller than a maximum width of the second segment of theabsorbent layer and may have converging sides, i.e., the inner endsegment may convergingly taper toward the inner end. The absorbent layermay have an overall shape similar to the shape of the replaceable corecomponent, as a whole. For example, the absorbent layer may have a shapeidentical to that of the replaceable core component, but reduced inscale, so as to fit at some distance inside the perimeter of thereplaceable core component. Alternatively, the absorbent layer andoverall replaceable core component may have different shapes. Forexample, the overall replaceable core component may have a substantiallyrectangular shape, while the absorbent layer inside it may have atapered shape.

As shown in FIG. 35 and FIG. 36, the replaceable core component mayinclude an extensible covering layer 300 attached to one end segment ofthe replaceable core component. The extensible covering layer ispreferably permanently attached to the replaceable core component in theouter end segment of the replaceable core component, such as bypermanent attachment means 301, and is preferably sufficientlyextensible to cover the used replaceable core component for disposal.Such an extensible covering layer may be releasably attached to thechassis when the replaceable core component is in the absorbent article,as shown in FIG. 35. During the removal of the replaceable corecomponent from the absorbent article in the direction indicated by thearrow 321, a portion of the extensible covering layer is temporarilyheld by the releasable attachment means 302 and the extensible coveringlayer is thereby extended to cover the replaceable core component as itis withdrawn, as shown in FIG. 36. Once the replaceable core componentis fully withdrawn from the chassis, the releasable attachment means mayrelease the extensible covering layer from the chassis and theextensible covering layer may then continue to cover the replaceablecore component. In some embodiments, the extensible covering layer maybe joined to an insertion tool in a first area of joining so as to bepeelably releasable and may be non-releasably joined to the replaceablecore component in a second area of joining. In such an embodiment, theextensible covering layer may be released from the insertion tool andreleasably attached to the chassis adjacent to the outer end of thereplaceable core component as the insertion tool is withdrawn from thechassis. When the replaceable core component is subsequently removedfrom the chassis, the extensible covering layer may remain attached tothe chassis, so as to extend to cover the outer surface of thereplaceable core component, and then may be released from the chassis.

The extensible covering layer 300 may be constructed in a number ofways. For example, the extensibility may be provided by the use of anextensible, preferably low modulus material, or alternatively by foldingor pleating the extensible covering layer so that removal of thereplaceable component extends or unfolds the extensible covering layerto cover the replaceable component, as shown in FIG. 37 and FIG. 38. Insome embodiments, the extensible covering layer may be plasticallyextensible or deformable. In exemplary embodiments including anextensible covering layer, the extensible covering layer preferablycovers less than 75% of the area of the replaceable core component priorto extension of the extensible covering layer and, more preferably,covers less than 50% of the area. In the embodiments in which theextensible covering layer is unfolded to provide the extension of theextensible covering layer, the extensible covering layer has at leastone fold, preferably at least two folds, and more preferably at leastthree folds. For embodiments comprising a folded extensible coveringlayer, the extensible covering layer preferably covers less than 75% ofthe area of the replaceable core component prior to extension of theextensible covering layer, more preferably less than 50% of the area,and most preferably less than 25% of the area. A combination of foldingand extensibility can also be used to form the extensible coveringlayer. In such an embodiment, the extensible covering layer may firstunfold and then extend, preferably through plastic deformation, to coverthe remainder of the replaceable core component. The extensible coveringlayer should extend to cover at least the permeable liquid transferregion of the replaceable core component and, preferably, the extensiblecovering layer extends beyond the inner end of the replaceable corecomponent as it is withdrawn. In some embodiments, the extensiblecovering layer may extend beyond the innermost end edge of thereplaceable core component and the releasable attachment means may meetto form a partial closure of the openable pocket formed by theextensible covering layer.

The replaceable core component may include a location stabilizer 310, asshown in FIG. 39 and FIG. 40, adapted to releasably retain thereplaceable core component in its fully inserted position, such as byreleasably attaching the replaceable core component to the chassis inthe waist region, in the crotch region, or in both regions. The locationstabilizer may include a mechanical surface fastener such as either ahook or a loop member disposed on the replaceable core component andadapted to engage a complementary member disposed on the chassis, or toengage a non-woven surface of the chassis. In some embodiments, thelocation stabilizer may include an adhesive disposed on the surface ofthe replaceable core component and adapted to releasably engage asurface of the chassis. Alternatively, the chassis may include alocation stabilizer adapted to releasably engage a surface of thereplaceable core component. In some embodiments, the location stabilizermay include a tab adapted to be inserted into a slot and therebyreleasably retain the replaceable core component in its fully insertedposition. For example, a tab on the replaceable core component may beinsertable into a slot in the chassis or vice versa. Such a tab disposedat the outer end segment of the replaceable core component may beinserted into a corresponding slot to serve as the location stabilizer310 while the replaceable core component is fully inserted and then maybe removed from the slot and used as the removal pull tab 46 when thereplaceable core component is removed from the chassis.

As is also shown in FIG. 39 and FIG. 40, the replaceable core componentmay include a pull tab 46 that can be used to remove the core componentfrom the chassis. Such a pull tab may include a gripping portion 237 tofacilitate control of the replaceable core component during its removal.The gripping portion may include a material with a higher coefficient offriction than the remainder of the surface of the replaceable corecomponent, or may have a textured surface,, to facilitate grasping thepull tab for removal. In some embodiments, the pull tab may have variousconfigurations, such as a configuration including a pull ring 236 intowhich a finger may be inserted to facilitate removal.

The replaceable core component may include an insertion depth indicator280 to provide an indication when a predetermined position of thereplaceable core component relative to the chassis is reached. Theinsertion depth indicator may include a visible indicator such as a line281 positioned in the outer end segment of the replaceable corecomponent, as shown in FIG. 41, such that the line is aligned with thewaist end edge 16 of the chassis when the predetermined position of thereplaceable core component is reached. In another example of a visibleinsertion depth indicator, as shown in FIG. 42 and FIG. 43, a graphicalobject 282 on the replaceable core component may align with an adjacentgraphical object 283 on the chassis to form a side-by-side compositegraphical object when the predetermined position of the replaceable corecomponent is reached. In yet another example of a visible insertiondepth indicator, as shown in FIG. 44 and FIG. 45, a graphical object 282on the replaceable core component may align with an adjacent graphicalobject 283 on the chassis to form an overlaid composite graphical objectwhen the predetermined position of the replaceable core component isreached. In the latter example, the graphical object 282 on thereplaceable core component may be visible through a translucent ortransparent portion of the chassis layer coinciding with the graphicalobject 283 on the chassis.

The insertion depth indicator may include a mechanical insertion depthindicator providing tactile feedback in some exemplary embodiments. Forexample, the insertion depth indicator may include a member disposed onthe replaceable core component, for example, a mechanical surfacefastener, such as either a hook member or a loop member, adapted toengage a complementary member disposed on the chassis or to engage anon-woven surface of the chassis when the predetermined position of thereplaceable core component is reached. In another example of amechanical insertion depth indicator, an outer surface of thereplaceable core component may have a relatively higher coefficient offriction to a portion of an adjacent surface of the chassis, such thatwhen the predetermined position of the replaceable core component isreached, an increase in the coefficient of friction markedly increasesthe force required to slide the replacement core component beyond thepredetermined position. Such a mechanical insertion depth indicator maybe disposed in the waist region, in the crotch region, or in bothregions. In addition, such a mechanical insertion depth indicator maysimultaneously serve as both an insertion depth indicator and a locationstabilizer. For example, each of the location stabilizers 310 shown inFIG. 39 and FIG. 40 may also serve as a mechanical insertion depthindicator. Alternative forms of a mechanical insertion depth indicatorare shown in FIG. 46 and FIG. 47, in which a mechanical insertion depthindicator 284 in the form of a protruding element prevents the insertionof the back panel 30 beyond a predetermined depth. As can be seen inthese figures, a mechanical insertion depth indicator can be locatedanywhere between the ends of a replaceable core component. Themechanical insertion depth indicator may include a laterally extendingor protruding element, in addition to or as an alternative to an elementgenerally oriented in the thickness dimension of the replaceable corecomponent such as described above. For example, the outer end segment ofa replaceable core component may include a laterally extending portionthat prevents the insertion of the back panel 30 beyond a predetermineddepth, thus functioning similarly to the mechanical insertion depthindicator 284 in the form of a protruding element depicted in FIG. 46and FIG. 47.

In some exemplary embodiments, an outer surface of the replaceable corecomponent or an element disposed on the outer surface may have adirectional coefficient of friction relative to the adjacent surfaces ofthe chassis and thereby provide tactile feedback related to whether ornot the replaceable core component is being inserted in the intendedend-to-end orientation. In such embodiments, a material forming thesurface of the replaceable core component and having directionalfrictional characteristics may be oriented such that when the inner endof the replaceable core component is inserted first, the coefficient ofsliding friction is relatively low, thus making the insertion of thereplaceable core component into the chassis relatively easy. On theother hand, if the insertion of an inverted replaceable core component,i.e., a replaceable core component oriented such that its outer end isbeing inserted first, is attempted, a relatively higher coefficient ofsliding friction of the directional material may provide a higherresistive force and, thus, make the insertion of the invertedreplaceable core component into the chassis relatively more difficult.Such a directional frictional surface material may include, for example,a fabric having a directional nap or grain, a sheet having orientedprotrusions or protuberances, a sheet having oriented teeth or hooks, orany other known structure having suitable directional frictionalcharacteristics.

For example, in FIG. 48 and FIG. 49, the directional coefficient offriction is illustratively represented by the angled teeth 287 pointingtoward the outer end 31 of the back panel 30 and the perpendicular teeth286, such that movement of the back panel 30 in one direction can bevisualized as causing the angled teeth to flex against the perpendicularteeth 286 and thereby present relatively little resistance to themovement, while movement of the back panel in an opposing direction canbe visualized as causing the angled teeth to jam against theperpendicular teeth and thereby present relatively greater resistance tomovement in this opposing direction. In FIG. 48, the back panel 30 isshown as oriented in the intended end-to-end orientation such that itsinner end 32 is being inserted first. In this figure, movement of theback panel 30 in an inward direction, i.e., in a direction from itsouter end 31 toward its inner end 32, can be visualized as causing theangled teeth 287 to flex against the perpendicular teeth 286 and therebypresent relatively little resistance to the inward movement. On theother hand, in FIG. 49, the back panel 30 is shown as orientedoppositely to the intended end-to-end orientation such that its outerend 31 is being inserted first. In this figure, movement of the backpanel 30 in an inward direction, i.e., in a direction from its inner end32 toward its outer end 31, can be visualized as causing the angledteeth 287 to jam against the perpendicular teeth 286 and thereby presentrelatively greater resistance to the inward movement.

The directional frictional characteristics may tend to resist theoutward movement of a replaceable core component that has been insertedin the intended end-to-end orientation in the chassis. For example,movement of the back panel 30 in FIG. 48 in an outward direction can bevisualized as causing the angled teeth 287 to jam against theperpendicular teeth 286 and thereby present relatively greaterresistance to the outward movement. Thus, an additional benefit of theuse of such a directionally frictional surface material is that therelatively high frictional force resisting the outward movement of areplaceable core component inserted in the intended predeterminedorientation may tend to assist in retaining the replaceable corecomponent in the intended predetermined position after its insertion andthis material may thereby serve as a location stabilizer.

In some exemplary embodiments, opposing outer surfaces of thereplaceable core component may have different coefficients of frictionrelative to the adjacent surfaces of the chassis and thereby providetactile feedback related to whether or not the replaceable corecomponent is being inserted in the intended orientation of itspredetermined wearer-facing and garment-facing surfaces. For example, insuch embodiments, a material forming the wearer-facing surface of thereplaceable core component and having directional frictionalcharacteristics may be oriented such that when the replaceable corecomponent is inserted with its predetermined wearer-facing surfaceoriented toward the wearer-facing layer of the chassis and with itspredetermined garment-facing surface oriented toward the garment-facinglayer of the chassis, the coefficient of sliding friction is relativelylow, thus making the insertion of the replaceable core component intothe chassis relatively easy. On the other hand, if the insertion of areversed replaceable core component, i.e., a replaceable core componentoriented such that its wearer-facing and garment-facing surfaces arereversed from its intended orientation, is attempted, a relativelyhigher coefficient of sliding friction of the directional material mayprovide a higher resistive force and, thus, make the insertion of thereversed replaceable core component into the chassis relatively moredifficult. Such a directional frictional surface material may include,for example, a fabric having a directional nap or grain, a sheet havingoriented protrusions or protuberances, a sheet having oriented teeth orhooks, or any other known structure having suitable directionalfrictional characteristics. This directional frictional surface materialmay be disposed on one or more of the major surfaces of the replaceablecore component or may be disposed on laterally opposing edge surfaces.

For example, in FIG. 50 and FIG. 51, the directional coefficient offriction is represented by the first angled teeth 285, pointing towardthe inner end 32 of the back panel 30, the second angled teeth 287,pointing toward the outer end 31 of the back panel 30, and theperpendicular teeth 286, such that movement of the back panel 30 in onedirection can be visualized as causing the angled teeth to flex againstthe perpendicular teeth 286 and thereby present relatively littleresistance to the movement, while movement of the back panel in anopposing direction can be visualized as causing the angled teeth to jamagainst the perpendicular teeth and thereby present relatively greaterresistance to movement in this opposing direction. In FIG. 50, the backpanel 30 is shown as oriented in the intended orientation of itspredetermined wearer-facing and garment-facing surfaces such that thesecond angled teeth 287 are oriented toward the perpendicular teeth 286and the first angled teeth 285 are oriented away from the perpendicularteeth 286. In this figure, movement of the back panel 30 in an inwarddirection, i.e., in a direction from its outer end 31 toward its innerend 32, can be visualized as causing the second angled teeth 287 to flexagainst the perpendicular teeth 286 and thereby present relativelylittle resistance to the inward movement. On the other hand, in FIG. 51,the back panel 30 is shown as oriented oppositely to the intendedorientation of its predetermined wearer-facing and garment-facingsurfaces such that the first angled teeth 285 are oriented toward theperpendicular teeth 286 and the second angled teeth 287 are orientedaway from the perpendicular teeth 286. In this figure, movement of theback panel 30 in an inward direction, i.e., in a direction from itsouter end 31 toward its inner end 32, can be visualized as causing thefirst angled teeth 285 to jam against the perpendicular teeth 286 andthereby present relatively greater resistance to the inward movement.

The directional frictional characteristics may tend to resist theoutward movement of a replaceable core component that has been insertedin the intended orientation of its predetermined wearer-facing andgarment-facing surfaces. For example, movement of the back panel 30 inFIG. 50 in an outward direction can be visualized as causing the secondangled teeth 287 to jam against the perpendicular teeth 286 and therebypresent relatively greater resistance to the outward movement. Thus, anadditional benefit of the use of such a directionally frictional surfacematerial is that the relatively high frictional force resisting theoutward movement of a replaceable core component inserted in theintended predetermined orientation may tend to assist in retaining thereplaceable core component in the intended predetermined position afterits insertion and this material may thereby serve as a locationstabilizer.

The elements having the directional frictional characteristics describedabove may be combined in various ways to provide tactile feedbackrelated to both related to whether or not the replaceable core componentis being inserted in the intended end-to-end orientation and whether ornot the replaceable core component is being inserted in the intendedorientation of its predetermined wearer-facing and garment-facingsurfaces. For example, as shown in FIG. 52, FIG. 53, FIG. 54, and FIG.55, each of the first angled teeth 285, pointing toward the inner end 32of the back panel 30, the second angled teeth 287, pointing toward theouter end 31 of the back panel 30, and the perpendicular teeth 286,again represent the directional coefficient of friction. In FIG. 52, theback panel 30 is oriented in the intended end-to-end orientation and inthe intended orientation of its predetermined wearer-facing andgarment-facing surfaces, such that movement of the back panel 30 in theinsertion direction 320 can be visualized as causing the second angledteeth 287a to flex against the perpendicular teeth 286 and therebypresent relatively little resistance to the movement. However, in FIG.53, the back panel 30 is shown as oriented oppositely to the intendedorientation of its predetermined wearer-facing and garment-facingsurfaces, such that movement of the back panel 30 in the insertiondirection 320 can be visualized as causing the first angled teeth 285 tojam against the perpendicular teeth 286 and thereby present relativelygreater resistance to the inward movement. Then, in FIG. 54, the backpanel 30 is shown as oriented oppositely to the intended end-to-endorientation such that its outer end 31 is being inserted first. In thisfigure, movement of the back panel 30 in an inward direction, i.e., in adirection from its inner end 32 toward its outer end 31, can bevisualized as causing the angled teeth 287 a to jam against theperpendicular teeth 286 and thereby present relatively greaterresistance to the inward movement. Finally, in FIG. 55, the back panel30 is shown as oriented oppositely to the intended end-to-endorientation and oppositely to the intended orientation of itspredetermined wearer-facing and garment-facing surfaces. In this figure,movement of the back panel 30 in an inward direction, i.e., in adirection from its inner end 32 toward its outer end 31, can bevisualized as causing the angled teeth 287 b to jam against theperpendicular teeth 286 and thereby present relatively greaterresistance to the inward movement.

As shown in FIG. 56, FIG. 57, FIG. 58, FIG. 59, FIG. 60, FIG. 61, FIG.62, FIG. 63, FIG. 64, and FIG. 65, the replaceable core component mayinclude an openable insertion pocket 260 into which a finger or fingersor an insertion tool 270 may be inserted for the application of a forceto insert the replaceable core component into the chassis in theintended predetermined orientation. Such an insertion force is appliedin a direction indicated by the arrow 320 from the outer end toward theinner end of the replaceable core component, e.g., in a direction fromthe outer end 31 toward the inner end 32 of the back panel 30. Forexample, the back panel 30 may have a piece of sheet material 261 joinedto its outer surface by continuous linear bonds or by an array of spotbonds, or any combination thereof, to form the openable insertion pockethaving an outer end edge 265, an inner end 264, and an openable end 263located at its outer end edge and facing toward the outer end 31 of theback panel 30. The bonds 262 may be formed by any means known in theart, including ultrasonic bonding, heat bonding, pressure bonding, oradhesive bonding. In general, any piece of sheet material joined alongat least two of its edges to an outer surface of the replaceable corecomponent may form the openable insertion pocket. However, such a sheetmay alternatively be bonded elsewhere, e.g., inboard of its edges, inany pattern that forms an openable pocket-like space that can similarlyserve as an openable insertion pocket, i.e., that can be used infunctional cooperation with the fingers or the insertion tool insertedinto this pocket-like space to exert an insertion force in the direction320 to insert the replaceable core component into the chassis in theintended predetermined orientation. For example, the bonds may have theform of the intermittent linear bonds 262 shown in FIG. 60 or the formof the spot bonds 262 shown in FIG. 61 and in FIG. 63. Such an openableinsertion pocket may be disposed on one major surface of the replaceablecore component or two openable insertion pockets may be disposed on theopposing major surfaces of the replaceable core component, as shown inFIG. 64 and FIG. 65. The openable insertion pocket is preferablydisposed in the inner end segment of the replaceable core component. Insome embodiments, an insertion tool may be predisposed inside theopenable insertion pocket of the replaceable core component.

The openable insertion pocket may be of sufficient size to accept only afinger or fingers, of sufficient size to accept an entire hand of acaregiver, or of sufficient size to accept an insertion tool. A lengthof the insert pocket may be measured along the longitudinal centerlineof the replaceable core component from the innermost end of the openableinsertion pocket adjacent to the inner end of the replaceable corecomponent to the outermost end of the openable insertion pocket. Thelength of the openable insertion pocket may be at least about 10% of thelength of the replaceable core component, as shown in FIG. 56, andpreferably is at least about 20%, as shown in FIG. 62, more preferablyis at least about 40%, as shown in FIG. 63, and most preferably is atleast about 60%, as shown in FIG. 58, of the length of the replaceablecore component. The insertion pocket sheet material may be liquidimpervious, but preferably is liquid pervious. The insertion pocketsheet material may be extensible to enable the openable insertion pocketto expand to accommodate the hand of the caregiver or to be wrappedaround a folded replaceable core component for disposal, as shown inFIG. 66, or around an end of an unfolded replaceable core component tocover a portion of the opposing surface for disposal. For example, theinsertion pocket sheet 261 shown in FIG. 67 may be folded around theinner end 32 of the back panel 30 to cover the permeable liquid transferregion 246 for disposal, as shown in FIG. 68. Preferably, the insertionpocket sheet material is elastically extensible. In some embodiments,the insertion pocket sheet 261 may be partially detachable, such as bymeans of perforations or a releasable adhesive attachment, from thesurface of the replaceable core component to allow the insertion pocketsheet to be folded over a portion of the replaceable core component andthereby cover the permeable liquid transfer region 246 of thereplaceable core component for disposal.

The replaceable core component may include a covering sheet 249, whichmay be liquid pervious or liquid impervious, covering a portion of afirst major surface 251 of the replaceable core component and wrappingover an edge of the replaceable core component, such as the inner end 32of the back panel 30, to cover at least a portion of the opposing secondmajor surface 252 of the replaceable core component, as shown in FIG.69. In such an embodiment, the wrapped over covering sheet 249 may forman openable insertion pocket 260 and thereby serve as an insertionpocket sheet 261 on one side of the replaceable core component, as shownin FIG. 70, or may form openable insertion pockets on both sides of thereplaceable core component. The covering sheet 249 can also be wrappedcompletely around the replaceable core component and joined where itsopposing edge margins overlap to form a tube-like structure envelopingthe replaceable core component. In some embodiments, such a coveringsheet that is liquid impervious may form a portion of the outer endsegment and/or a portion of the pull tab, thereby preventing liquid inthe absorbent layer from wetting the outer surface of this portion ofthe replaceable core component.

The openable insertion pocket 260 may also be formed internally to thereplaceable core component. For example, an internal insertion pocket260 may be formed in the back panel 30 between an absorbent layer 34 anda superposed absorbent layer 36, as shown in FIG. 71, between anabsorbent layer 34 and an inner layer 266, as shown in FIG. 72, orbetween two inner layers 266 a and 266 b, as shown in FIG. 73. In suchan embodiment, a finger or fingers or an insertion tool may be insertedinto the internal insertion pocket for the application of a force toinsert the replaceable core component into the chassis in the intendedpredetermined orientation. The layers forming the internal insertionpocket may be liquid pervious, thereby permitting the passage of liquidfrom one absorbent layer of the replaceable core component to anotherabsorbent layer disposed on the opposing side of the internal insertionpocket. Alternatively, one or more of the layers forming the internalinsertion pocket may be liquid impervious and thereby act as a barrierto liquid flow between the absorbent layer or layers and the internalinsertion pocket. For example, the inner layer 266 may be liquidpervious or liquid impervious.

A replaceable core component having an internal insertion pocket mayinclude an inverting pull tab 268 disposed inside the internal insertionpocket and extending from the inner end 264 of the internal insertionpocket adjacent to the inner end segment of the replaceable corecomponent toward the outer end segment of the replaceable corecomponent, as shown in FIG. 74. When the inverting pull tab is pulledtoward the outer end of the replaceable core component, the replaceablecore component is inverted, i.e., turned inside out, by drawing theinner end of the replaceable core component into and through theinternal insertion pocket, such that the original outer layers of thereplaceable core component are drawn inside and the original innerlayers of the internal insertion pocket are drawn to the outside of theinverted replaceable core component. In other words, when inverted, thereplaceable core component is turned inside out and wrapped within theoriginal inner layers 266, as shown in FIG. 75. In this invertableembodiment, it is preferred that the inner layers be liquid impervious,so that the inverted replaceable core component is wrapped within theseliquid impermeable layers for disposal. Also, the outer end segment ofthe replaceable core component may be releasably attached to the chassiswhen the replaceable core component is in the absorbent article, suchthat during removal of the replaceable core component from the absorbentarticle, the outer end segment is temporarily held by the releasableattachment means 305, thereby causing the replaceable core component toinvert, i.e., turn inside out, as it is withdrawn. Once the replaceablecore component is fully withdrawn from the chassis, the releasableattachment means may release the outer end segment and the originalinner layers may then continue to cover the replaceable core component.In some embodiments, the releasable attachment means may be fastenedtogether to secure the replaceable core component in the invertedconfiguration.

The replaceable core component needs to extend only from the crotchregion to one of the waist regions of the article. However, thereplaceable core component preferably extends from the crotch regionbeyond a waist end edge of one of the waist regions, so that the outerend of the replaceable core component is exposed and thereby visiblewhen the absorbent article is worn. To this point in this disclosure,the outer end 31 of the back panel 30 has been shown extending beyondthe adjacent waist end edge 16 in this manner in FIG. 17, FIG. 18, FIG.28, FIG. 41, FIG. 43, and FIG. 45.

A portion of the replaceable core component extending beyond the waistend edge may include a liquid presence indicator 290 adapted to providean indication of a wetted condition of the replaceable core component.The liquid presence indicator may include multiple strips 291 of wickingmaterial, as shown in FIG. 76, which may have differing characteristicssuch as the lengths of the strips, the thicknesses of the strips, theshapes and areas of the strips, the pore sizes of the wicking materialsused in the various strips, the absorbent capacities of the strips, thedegrees of hydrophilicity of the strips, and etc. A single wicking strip291 may also be used, as shown in FIG. 77. A suitable wicking strip 291may have a 30 minute vertical wicking height of at least 10 cm and,preferably, may have a 30 minute vertical wicking height of at least 20cm or, more preferably, of at least 30 cm. The wicking strips mayinclude such materials as high surface area fibers, capillary channelfilaments, open celled polymeric foams, and/or densified cellulosesubstrates. The wicking strips may be disposed within the replaceablecore component, e.g., the back panel 30, such that at least one of thewicking strips extends from the permeable liquid transfer region of thereplaceable core component to the outer end segment. Each of the wickingstrips is preferably in capillary liquid communication with at least aportion of the storage/redistribution member of the replaceable corecomponent. A portion of the wicking strip may also be isolated from thestorage/redistribution member by a liquid impermeable layer 293 disposedbetween the wicking strip and the absorbent layer of the replaceablecore component. The wicking strip may have a visible liquid presenceindication means 292 disposed on or adjacent to its outer end. Thevisible indication means may include a pH-activated ormoisture-activated material, which may be applied to the wicking stripin the form of a hotmelt adhesive in some exemplary embodiments.Preferably, the visible indication means is visible through the materialforming the outer surface of the replaceable core component, making itunnecessary for the wicking strip or strips to extend beyond the outerend of the replaceable core component in order to be visible.

In some exemplary embodiments, the liquid presence indicator 290 mayinclude an indicating composition disposed on an absorbent layer of thereplaceable core component, such as a storage member or astorage/redistribution member, as shown in FIG. 77. Such an indicatingcomposition may preferably be disposed on the absorbent layer in theouter end segment of the replaceable core component. The indicatingcomposition may provide a visible indication and may include apH-activated or moisture-activated material, which may be applied to theabsorbent layer in the form of a hotmelt adhesive or a water-soluble dyein some exemplary embodiments. The visible liquid presence indicationmeans 292 is preferably disposed above the waist end edge of the chassiswhen the replaceable core component is inserted to the intendedpredetermined depth in the chassis.

However, in some embodiments, the visible indication means may bedisposed below the waist end edge, i.e., between the backsheet and thewearer in the waist region of the article, when the replaceable corecomponent is inserted to the intended predetermined depth. For example,a stationary absorbent strip 294 including a litmus paper-like substratethat changes color in a wetted area 296, as shown in FIG. 78, or aseries of visible liquid presence indication means 292, as shown in FIG.79, may undergo a visible change in response to a liquid presence or tothe pH of a liquid contacting the indication means. As another example,a pH-activated or moisture-activated material may be S applied in astripe on the outer surface of the replaceable core component. Theseapproaches of providing a “liquid level” indication enable the user toassess the actual level of liquid loading in the replaceable corecomponent, in addition to determining the presence of liquid. In someembodiments, the visible indication means may be visible through thebacksheet when the replaceable core component is inserted to theintended predetermined depth. The replaceable core component may have atranslucent or transparent region through which the liquid presenceindication means is visible and, in some embodiments, a replaceable corecomponent having a visible liquid presence indication means may be usedin a chassis having a transparent or translucent region in the backsheetthat aligns with the visible indication means when the replaceable corecomponent is inserted into the article to the intended predetermineddepth and in the intended predetermined position and orientation.

Some exemplary embodiments may have a “dipstick” type visible liquidpresence indicator, as shown in FIG. 80, in which an absorbent strip 294can be moved through a slit 295 in an outer layer of the replaceablecore component between a fully inserted position within the replaceablecore component and a partially inserted position, thereby exposing aninner portion of the visible liquid presence indication absorbent stripand facilitating a determination of the level to which the replaceablecore component has been wetted. The usage of such a “dipstick” typevisible liquid presence indication absorbent strip is similar to that ofusing a dipstick to check the fluid levels in an automobile engine, thefuel level in an aircraft fuel tank, or the level in an in-groundstorage tank. The “dipstick” type visible liquid presence indicationabsorbent strip can include a litmus paper-like substrate that changescolor in a wetted area 296, as shown in FIG. 81, or can include a seriesof visible liquid presence indication means 292, as shown in FIG. 82,each of which undergoes a visible change in response to a liquidpresence or to the pH of a liquid contacting the indication means. Thedipstick approach enables the user to assess the actual level of liquidloading in the replaceable core component, in addition to determiningthe presence of liquid.

In some embodiments, the liquid presence indicator may include awater-sensitive restraining element whose dimension, tensile strength,resistance to compression, resistance to bending, or resistance tobuckling is altered when it is contacted by water. The water-sensitiverestraining element may include a water soluble material or a materialthat weakens, but does not dissolve, when wetted, such as cellulosicmaterial. For example, as shown in FIG. 83 and FIG. 84, the liquidpresence indicator may include a water-sensitive restraining element 297joined to an elongated elastic force-generating element 298, either byjoining the elastic element directly to the water-sensitive element orby attaching the water-sensitive element to an intermediate element thatis attached to the elastic element. In its initial dry state, thewater-sensitive element restrains the elastic element in its elongatedstate. When the water-sensitive element comes into contact with liquidas the product is loaded with bodily exudates, the water-sensitiveelement dissolves and releases the elastic element, thereby allowing theelastic element to relax by contracting. The resultant contraction ofthe elastic element moves a movable indicator strip 299 toward the innerend 32 of the back panel 30 to expose a visible liquid presenceindication means 292 and thereby indicate the presence of liquid in thereplaceable core component.

In other embodiments, the elastic force-generating element may initiallybe compressed, rather than elongated, and may relax by expanding, ratherthan contracting, when it is released. For example, as shown in FIG. 85and FIG. 86, the visible liquid presence indication means 292 isdisposed on the movable indicator strip 299 and is initially hiddenbelow the waist end edge 16 of the chassis. The elastic element 298 isrestrained in its initial compressed state by the water-sensitiverestraining element 297. When the water-sensitive element comes intocontact with liquid as the product is loaded with bodily exudates, thewater-sensitive element dissolves and releases the elastic element,thereby allowing the elastic element to relax by expanding. Theresultant expansion of the elastic element moves the movable indicatorstrip 299 toward the outer end 31 of the back panel 30, which outer endextends beyond the waist end edge of the chassis, to expose the visibleliquid presence indication means 292 and thereby indicate the presenceof liquid in the replaceable core component.

In some embodiments, a liquid presence indicator having a similarstructure may provide a tactile indication of the presence of liquid inthe replaceable core component. For example, when released, the elasticelement may move a movable tactile indicator strip to a predeterminedposition in which the thickness of the strip provides the tactileimpression of a raised area or a protuberance. As another example, whenreleased, the elastic element may move a movable tactile indicator stripaway from its initial position in which the thickness of the stripprovided the tactile impression of a raised area or a protuberance andthereby eliminate that tactile impression, i.e., make the initiallyraised or protruding area feel smooth or flat.

The Insertion Tool

In order for the replaceable core component to be comfortable duringwear, the replaceable core component is preferably relatively soft,relatively thin, and relatively flexible. However, the flexibility maymake the insertion of the replaceable core component, by itself,difficult. For example, an attempt to insert the replaceable corecomponent by grasping its outer end and pushing it into the chassis mayresult in the replaceable core component collapsing or buckling due tothe sliding resistance between its outer surfaces and the adjacentsurfaces of the chassis. Similarly, an attempt to insert the replaceablecore component by grasping its inner end and inserting the grasping handinto the chassis may lead to wrinkling or folding of the replaceablecore component. Also, the grasping hand may be too large to fit into thespace into which the replaceable core component is being inserted and,therefore, only a partial insertion may be achieved.

Thus, the use of an insertion tool having a suitable thickness, asuitable stiffness, and a suitable buckling resistance may facilitatethe insertion of the replaceable core component. Therefore, an absorbentarticle of the present invention may include an insertion tool for usein the application of a force to insert the replaceable core componentinto the chassis in the intended predetermined orientation. The use ofsuch an insertion tool may obviate the need for a caregiver to inserther hand into the absorbent article when inserting a replaceable corecomponent. Also, a suitable insertion tool may be significantly thinnerthan a human hand and thus facilitate the deeper insertion of thereplaceable core component into the chassis, including when the chassis,or the margin of the openable end of an openable chassis pocket, islimited in its extensibility to accommodate the insertion. In differentembodiments, the insertion tool may be withdrawn following the insertionof the replaceable core component or may remain in the chassis. Also,the insertion tool may be used without being attached to the replaceablecore component, may be attached to the replaceable core component forits insertion and then detached from the replaceable core component, ormay remain attached to the replaceable core component.

The insertion tool 270 may be inserted into an insertion pocket 260attached on the outside of a replaceable core component, such as in theexemplary embodiments shown in FIG. 87, FIG. 88, FIG. 89, FIG. 90, FIG.91, and FIG. 92, or it may be inserted into an internal insertion pocketformed internally of the replaceable core component, as describedelsewhere in this disclosure. In some embodiments, two insertion toolsmay be inserted into two insertion pockets disposed on the opposingmajor surfaces of the replaceable core component, as shown in FIG. 93.When used in this manner, the two insertion tools may act as barrierspreventing the exposure of the replaceable core component, for example,to the hand of a caregiver inserting the replaceable core component intothe absorbent article. In addition, the surfaces of the two insertiontools may have a relatively low coefficient of friction to the adjacentmaterials of the chassis and thereby facilitate the insertion of thereplaceable core component. Once it is inserted into the insertionpocket 260, the insertion tool 270 may be used to exert an insertionforce in the direction indicated by the arrow 320 to insert thereplaceable core component into the chassis. Then, the insertion toolmay be withdrawn from the chassis in the opposing direction indicated bythe arrow 321.

Such an insertion tool preferably has a planar surface area that issufficiently large to aid in preventing the wrinkling or folding of theabsorbent layer or layers of the replaceable core component during itsinsertion. To this end, the insertion tool preferably has a planarsurface area of at least about 25% of the planar surface area of thereplaceable core component. More preferably, the insertion tool has aplanar surface area of at least about 50% or, most preferably, at leastabout 75%, of the planar surface area of the replaceable core component.The insertion tool may also be shaped to spread the replaceable corecomponent and thereby prevent its wrinkling or folding during insertion.For example, as shown in the figures, the portion of the insertion tooladjacent to its inner end 318 is sized and shaped to conform to thetapered shape of the inner end segment of the absorbent layer 34 of theback panel 30.

Alternatively, the insertion tool may be releasably attached to thereplaceable core component in a manner that is suitable for theeffective insertion of the replaceable core component into the chassis.In such an embodiment, after the replaceable core component is inserted,the insertion tool may be released from the replaceable core componentas the insertion tool is withdrawn from the chassis, as shown in FIG.94, and FIG. 95. For example, the insertion tool 270 may be affixedadjacent to its inner end 318 to an intermediate member 315 in a firstarea of joining 316 and the replaceable core component may be joined tothe intermediate member in a second area of joining 317 so as to bepeelably releasable. In such an embodiment, the intermediate member maybe disposed such that the intermediate member is subjected to a tensileforce and the first area of joining and the second area of joining aresubjected to substantially only a shear force as the insertion tool isused to apply an insertion force in the direction indicated by the arrow320 to insert the replaceable core component into the chassis. Then,when the insertion tool is withdrawn from the chassis in the directionindicated by the arrow 321, the second area of joining is subjected to apeel force such that the intermediate member is released from thereplaceable core component, while remaining affixed to the insertiontool and thereby being withdrawn with the insertion tool.

As another example, the insertion tool 270 may be joined adjacent to itsinner end 318 to the intermediate member 315 in the first area ofjoining 316 so as to be peelably releasable and the replaceable corecomponent may be affixed to the intermediate member in the second areaof joining 317. In such an embodiment, the intermediate member may besimilarly subjected to a tensile force and the first area of joining andthe second area of joining may similarly be subjected to substantiallyonly a shear force as the insertion tool is used to apply a force in thedirection 320 to insert the replaceable core component into the chassis.Then, when the insertion tool is withdrawn from the chassis in thedirection indicated by the arrow 321, and the first area of joining isthereby subjected to a peel force, the insertion tool may be releasedfrom the intermediate member, which remains affixed to the replaceablecore component.

Rather than being joined or attached to the replaceable core componenteither directly or through an intermediate member, the insertion toolmay have one or more protuberances, such as angled teeth or hooks, thatengage the layer forming the outer surface of the replaceable corecomponent when the insertion tool is slid along the outer surface in afirst direction, and that disengage or fail to engage when the insertiontool is slid along the outer surface in an opposing second direction.Alternatively, the insertion tool may engage such protuberances on theouter surface of the replaceable core component. In eitherconfiguration, the movement of the insertion tool in the first directionapplies an insertion force to the replaceable core component, while themovement of the insertion tool in the second direction disengages theinsertion tool from the replaceable core component, thus leaving thereplaceable core component in the inserted position. A surface of theinsertion tool having a directional coefficient of friction relative tothe outer surface layer of the replaceable core component may performthe same function as the protuberance by providing greater resistancewhen slid along the outer surface of the replaceable core component inthe insertion direction and lesser resistance when withdrawn in theopposing direction.

In some embodiments, the extensible covering layer 300 shown in FIG. 35,FIG. 36, FIG. 37, and FIG. 38 may serve as the intermediate member 315that remains attached to the replaceable core component after thewithdrawal of the insertion tool. In such an embodiment, the extensiblecovering layer 300/intermediate member 315 may be releasably attached tothe insertion tool for the insertion of the replaceable core componentinto the absorbent article. As the insertion tool is withdrawn, theextensible covering layer/intermediate member may be released from theinsertion tool and attached to the chassis, as shown in FIG. 35 and FIG.37. For example, in some embodiments, the extensible coveringlayer/intermediate member may be releasably attached to the insertiontool by releasable attachment means 302, which may be exposed by thewithdrawal of the insertion tool and may then become attached to thechassis. In other embodiments, a second releasable attachment meansdisposed on the surface of the extensible covering layer/intermediatemember opposite the releasable attachment means 302 may be exposed bythe withdrawal of the insertion tool and may then become attached to thechassis. Similarly, a releasable attachment means having directionalcharacteristics may be disposed adjacent to the releasable attachment ofthe extensible covering layer/intermediate member to the insertion tool.Such a directional releasable attachment means may not engage thechassis when moved in the insertion direction, but may engage thechassis when the insertion tool is removed. When the replaceable corecomponent is subsequently removed from the chassis, the extensiblecovering layer may remain attached to the chassis, so as to extend tocover the outer surface of the replaceable core component as shown inFIG. 36 and FIG. 38, and then may be released from the chassis.

The insertion tool may include an insertion depth indicator to providean indication when a predetermined position of the insertion toolcorresponding to a predetermined position of the replaceable corecomponent relative to the chassis is reached. In general, the insertiontool may include any of the forms of an insertion depth indicatordescribed with regard to the replaceable core component. For example, asshown in FIG. 88, the insertion depth indicator may include a visibleindicator such as a line 281 positioned adjacent to the outer end 319 ofthe insertion tool such that the line is aligned with the waist end edgeof the chassis when the predetermined position is reached. In anotherexample of a visible insertion depth indicator, a graphical object onthe insertion tool may align with an adjacent graphical object on thechassis to form a composite graphical object when the predeterminedposition is reached, similarly to the way in which a similar graphicalobject on the replaceable core component is herein described asaligning.

The insertion tool's insertion depth indicator may include a mechanicalindicator providing tactile feedback in some exemplary embodiments. Forexample, as shown in FIG. 89, FIG. 90, FIG. 91, and FIG. 92, theinsertion depth indicator of the insertion tool may include a mechanicalinsertion depth indicator 284 in the form of a mechanical surfacefastener such as either a hook or a loop member disposed on theinsertion tool and adapted to engage a complementary member disposed onthe chassis, or to engage a non-woven surface of the chassis, when thepredetermined position is reached. In another example of a mechanicalinsertion depth indicator, an outer surface of the insertion tool mayhave a relatively higher coefficient of friction to a portion of anadjacent surface of the chassis, such that when the predeterminedposition is reached, an increase in the coefficient of friction markedlyincreases the force required to slide the insertion tool farther and,thus, to insert the replaceable core component beyond the predeterminedposition. In addition, such a mechanical insertion depth indicator maysimultaneously serve as both an insertion depth indicator and a locationstabilizer, in embodiments in which the insertion tool remains in thechassis with the replaceable core component.

In some exemplary embodiments, an outer surface of the insertion toolmay have a directional coefficient of friction relative to the adjacentsurfaces of the chassis and thereby provide tactile feedback related towhether or not the insertion tool and the replaceable core component arebeing inserted in the intended end-to-end orientation. In general, theinsertion tool may include any of the forms of such surfaces havingdirectional coefficients of friction described with regard to thereplaceable core component. For example, a material forming the surfaceof the insertion tool and having directional frictional characteristicsmay be oriented such that when the inner end of the insertion tool isinserted first, the coefficient of sliding friction is relatively low,thus making the insertion of the insertion tool and the replaceable corecomponent into the chassis relatively easy. On the other hand, if theinsertion of an inverted insertion tool, i.e., an insertion tooloriented such that its outer end is being inserted first, is attempted,a relatively higher coefficient of sliding friction of the directionalmaterial may provide a higher resistive force and, thus, make theinsertion of the inverted insertion tool and replaceable core componentinto the chassis relatively more difficult. This directional frictionalsurface material may be disposed on one or more of the major surfaces ofthe insertion tool or may be disposed on laterally opposing edgesurfaces.

In some exemplary embodiments, opposing outer surfaces of the insertiontool may have different coefficients of friction relative to theadjacent surfaces of the chassis and thereby provide tactile feedbackrelated to whether or not the insertion tool and the replaceable corecomponent are being inserted in the intended orientation of thereplaceable core component's predetermined wearer-facing andgarment-facing surfaces. For example, a material forming thewearer-facing surface of the insertion tool and having directionalfrictional characteristics may be oriented such that when the insertiontool is inserted with its predetermined wearer-facing surface orientedtoward the wearer-facing layer of the chassis and with its predeterminedgarment-facing surface oriented toward the garment-facing layer of thechassis, the coefficient of sliding friction is relatively low, thusmaking the insertion of the insertion tool and the replaceable corecomponent into the chassis relatively easy. On the other hand, if theinsertion of a reversed insertion tool, i.e., an insertion tool orientedsuch that its wearer-facing and garment-facing surfaces are reversedfrom its intended orientation, is attempted, a relatively highercoefficient of sliding friction of the directional material may providea higher resistive force and, thus, make the insertion of the reversedinsertion tool and replaceable core component into the chassisrelatively more difficult.

The insertion tool may include a planar card-like element 271, as shownin FIG. 96. In order to be suitably thin and have a planar surface areathat is sufficiently large to aid in preventing the wrinkling or foldingof the replaceable core component during its insertion, this card-likeelement preferably has a relatively high ratio of its average width toits average thickness. For example, the card-like element may have anaverage width to average thickness ratio of at least 25:1. Preferably,the card-like element may have an average width to average thicknessratio of at least about 50:1 and, more preferably, at least about 100:1and, most preferably, at least about 300:1. In some embodiments, theinsertion tool may include two such planar card-like elements in asuperposed configuration that are separable from each other along atleast a portion of the perimeter of one or both of the superposed planarcard-like elements. The planar card-like element may provide the desiredstiffness to facilitate the insertion of the replaceable core componentinto the chassis. In embodiments in which the layers forming theinsertion pocket of the replaceable absorbent core component and/or thelayers forming the openable chassis pocket into which the replaceablecore component is being inserted provide a constraining force tending toprevent the deflection of the replaceable core component and theinsertion tool from a smooth plane or curved planar shape during theinsertion process, this constraining force may lessen the requiredstiffness of the insertion tool.

Such an insertion tool may also include a bag-like element 272 formingan openable insertion tool pocket 273, as shown in an open state in FIG.96. The bag like element may be joined to one side of the planarcard-like element, as in FIG. 96, or alternatively, the bag-like elementmay be disposed between and joined to two planar card-like elements, asshown in FIG. 97. The bag-like element may be made of an extensiblesheet material or may be formed of a sheet having folds or pleats 277 soas to be expandable for opening. The openable insertion tool pocket 273may be of sufficient size to accept and retain a replaceable corecomponent. Thus, the openable insertion tool pocket may be used tocontain an unused replaceable core component prior to use or to acceptand contain a used replaceable core component for disposal. The bag-likestructure of the insertion tool may include a closure means, such as atie-style closure that may include one or more closure tabs 274, asshown in FIG. 98, a drawstring closure, a mechanical fastener, a zipper,a button, a snap, an adhesive closure, or another closure means known inthe art. In embodiments in which the unused replaceable core componentis disposed inside the openable insertion tool pocket, this closuremeans may be used to secure the replaceable core component inside thepocket prior to its insertion into the absorbent article. This closuremeans may also be used to secure a used replaceable core componentinside the openable insertion tool pocket after its removal from theabsorbent article.

In some embodiments, an insertion tool having the form of a card-likeelement 271 and an attached bag-like element 272 may be inserted into aninsertion pocket of a replaceable core component and used in the mannerdescribed to exert an insertion force. Also, in some embodiments, asshown in FIG. 99 and FIG. 100, a replaceable core component, such asback panel 30, may be disposed inside the openable insertion tool pocket273 prior to its insertion into the absorbent article. In such anembodiment, the insertion tool containing the replaceable core componentinside its openable insertion tool pocket may be inserted into theabsorbent article and then withdrawn, thereby leaving the replaceablecore component in the absorbent article. When used in this manner, thecard-like element and/or the bag-like element of the insertion tool mayact as a barrier preventing the exposure of the replaceable corecomponent, for example, to the hand of a caregiver inserting thereplaceable core component into the absorbent article or to potentialcontaminants prior to its insertion into the absorbent article.

In some embodiments, a replaceable core component including theextensible covering layer 300 shown in FIG. 35 and FIG. 36 may bedisposed inside the openable insertion tool pocket 273, as shown in FIG.99, for insertion into the absorbent article. In such an embodiment, thereleasable attachment means 302 may serve to attach the extensiblecovering layer 300 to the insertion tool in the first area of joining316 so as to be peelably releasable. As the insertion tool is withdrawn,it may be peelably released from the extensible covering layer 300 andthe releasable attachment means 302 may become exposed and attached tothe chassis, as shown in FIG. 35. When the replaceable core component issubsequently removed from the chassis, the extensible covering layer mayremain attached to the chassis, so as to extend to cover the outersurface of the replaceable core component as shown in FIG. 36, and thenmay be released from the chassis.

The insertion tool may have a substantially planar portion having agenerally uniform thickness and a portion adjacent to its inner endhaving a greater thickness and thereby serving as a “plow” to separatethe separable layers of the chassis as the insertion tool in insertedinto the absorbent article. The greater thickness 276 of the insertiontool in the end portion, relative to the generally uniform thickness 275in the planar portion, may be formed by folding the inner end 318 of theinsertion tool 270 upon itself, for example as shown in FIG. 101 andFIG. 102, by forming a bend in the inner end, for example as in FIG. 103and FIG. 104, by adding a layer to the inner end, for example as in FIG.105 and FIG. 106, or by simply forming the inner end of the insertiontool with a greater planar thickness. The greater thickness of theinsertion tool in the end portion may be at least about 5 times thegenerally uniform thickness in the substantially planar portion and is,preferably, at least about 10 times or, more preferably, at least about20 times the generally uniform thickness. In some embodiments, theinsertion tool may include a resilient element 278 serving to make therelatively thicker region elastically compressible and therebyfacilitate the use of the insertion tool by allowing it to resilientlyconform as it is inserted into an insertion pocket and as it is used toexert a force to insert a replaceable core component into a chassis.

In embodiments in which the openable chassis pocket and the replaceablecore component are “keyed” to each other, so as to prevent the insertionof the replaceable core component in any orientation other than apredetermined orientation contemplated in the design of the replaceablecore component, the insertion tool may be correspondingly keyed to theopenable chassis pocket and the replaceable core component. Thus, theopenable chassis pocket may be shaped and the insertion tool may becorrespondingly shaped to fit within the shaped openable chassis pocket.

For example, in embodiments described in detail elsewhere in thisdisclosure, the openable chassis pocket may include a separator thatbifurcates or partitions the openable chassis pocket into at least twoconnected branches. In embodiments having such a bifurcated openablechassis pocket, the insertion tool may include a cooperative structurethat permits the insertion of its inner end beyond the outer end of theseparator, i.e., to a point farther from the waist end edge than theouter end of the separator. Such a cooperative structure 227 in theinsertion tool may include a slit, a slot, or a groove formed in theinsertion tool, as shown in FIG. 107, for receiving and/or bypassing theseparator. The separator in the openable chassis pocket may be formedalong the longitudinal centerline 17 of the chassis and the cooperativestructure in the insertion tool may be formed so as to coincide with thelongitudinal centerline 25 of the replaceable core component or,alternatively, either the separator or the cooperative structure, orboth, may be offset from the respective longitudinal centerline, as inFIG. 107. Similarly to the manner described with regard to thecooperative structure in the replaceable core component, such an offsetconfiguration may serve to ensure that the insertion tool is insertedwith its inner end in the crotch region and its outer end in the waistregion and is inserted in a predetermined lateral position, therebyensuring that the replaceable core component being inserted with theinsertion tool is inserted with its liquid pervious surface region in apredetermined longitudinal and/or lateral position, and so on. As shownin FIG. 108, in embodiments in which the openable chassis pocket isdivided into several separate connected branches or non-interconnectedsections, i.e., divided effectively into separate openable chassispockets, the insertion tool may have a corresponding number ofprotruding finger-like sections 279. These finger-like sections may beplaced into the branches or sections of the openable chassis pocket in aside-by-side lateral relationship and, thus, may be used to insert acorrespondingly shaped replaceable core component or to insert multiplereplaceable core component into the respective branches or sections.

In embodiments including more than one shaping element, as well asshaping elements other than a separator, the insertion tool may becorrespondingly shaped. For example, a shaping element may include aslot into which a corresponding “key” fits in only a predeterminedorientation, one or more holes or depressions into which one or morecorresponding pins, bosses, or protuberances fits in only apredetermined orientation, a partition within the openable chassispocket that requires the insertion tool to be partially inserted andthen rotated and/or translated in order for the insertion to becompleted, and similar configurations.

Those skilled in the art will recognize that additional exemplaryembodiments of absorbent articles providing access to a removable andreplaceable absorbent core component or absorbent insert are possiblewithout departing from the scope of the present invention. Furthermore,it is contemplated that, without departing from the scope of the presentinvention, additional combinations of the absorbent core components, theabsorbent core members, the placement of the absorbent core componentsand members, and the absorptive characteristics may be used, with thedesired functional requirements influencing the ultimate design.Specifically, not only the illustrated embodiments, but all structurallyfeasible combinations of the disclosed elements and configurations arecontemplated. Also, methods of use of the disposable absorbent articlesof the present invention in which the replaceable core component isremoved, inserted, and/or replaced are contemplated. In addition,articles of commerce, such as packages, bags, containers, display packs,and the like, in which the disposable absorbent articles of the presentinvention are included with instructions for their use are likewisecontemplated.

While particular exemplary embodiments of the present invention havebeen illustrated and described, it would be obvious to those skilled inthe art that various other changes and modifications can be made withoutdeparting from the spirit and scope of the present invention. It istherefore intended to encompass in the appended claims all such changesand modifications that are within the scope of the present invention.

1. A disposable absorbent article adapted to be worn about a lower torsoof a human body, comprising: a chassis forming a waist opening and apair of leg openings and having longitudinally opposing first and secondwaist end edges, longitudinally opposing first and second waist regionsadjacent to the respective waist end edge, and a crotch regionlongitudinally intermediate of the waist regions, the chassis comprisinga chassis topsheet having a wearer-facing surface disposed such that atleast a portion of the wearer-facing surface contacts the body when thearticle is worn, and a chassis backsheet defining a garment-facingsurface of the article; a non-removable absorbent core componentdisposed in the crotch region between the chassis topsheet and thechassis backsheet; a first replaceable absorbent core component disposedbetween the chassis topsheet and the chassis backsheet and in capillaryliquid communication with the non-removable absorbent core component,the first replaceable absorbent core component having a structuredistinct from the chassis topsheet; the chassis and the firstreplaceable absorbent core component being adapted to allow removal ofthe first replaceable absorbent core component from between the chassistopsheet and the chassis backsheet without removal of the chassistopsheet, and replacement of the first replaceable absorbent corecomponent with a second replaceable absorbent core component between thechassis topsheet and the chassis backsheet, and for continued usefollowing such replacement; and a releasable and reusable fastenercomponent adapted to allow release therefrom and provide attachmentthereto following a release therefrom, disposed on and situated so as toeffect releasable and repeatable retention of a removable absorbent corecomponent between said topsheet and said backsheet; wherein thenon-removable absorbent core component comprises absorbent layers andthe replaceable absorbent core component is disposed between theabsorbent lavers.
 2. The disposable absorbent article of claim 1 whereinthe replaceable absorbent core component extends from the first waistregion into and ends in the crotch region.
 3. The disposable absorbentarticle of claim 1 wherein the chassis and the replaceable absorbentcore component are adapted to allow removal and replacement of thereplaceable absorbent core component while the absorbent article isbeing worn by a wearer.
 4. A disposable absorbent article adapted to beworn about a lower torso of a human body, comprising: a chassis forminga waist opening and a pair of leg openings and having longitudinallyopposing first and second waist end edges, longitudinally opposing firstand second waist regions adjacent to the respective waist end edge, anda crotch region longitudinally intermediate of the waist regions, thechassis comprising a chassis topsheet having a wearer-facing surfacedisposed such that at least a portion of the wearer-facing surfacecontacts the body when the article is worn, and a chassis backsheetdefining a garment-facing surface of the article; a non-removableabsorbent core component disposed in the crotch region between thechassis topsheet and the chassis backsheet; a first replaceableabsorbent core component disposed between the topsheet and the backsheetand in capillary liquid communication with the non-removable absorbentcore component, the first replaceable absorbent core component having astructure distinct from the chassis topsheet; the chassis and the firstreplaceable absorbent core component being adapted to allow removal ofthe first replaceable absorbent core component from between the chassistopsheet and the chassis backsheet without removal of the chassistopsheet, and replacement of the first replaceable absorbent corecomponent with a second replaceable absorbent core component between thechassis topsheet and the chassis backsheet, and for continued usefollowing such replacement; and a releasable location stabilizer adaptedto provide attachment thereby and allow release thereof, disposed onsaid first replaceable absorbent core component and situated so as toeffect releasable attachment and retention of said first replaceableabsorbent core component between said topsheet and said backsheet;wherein the non-removable absorbent core component comprises absorbentlayers and the replaceable absorbent core component is disposed betweenthe absorbent layers.
 5. A disposable absorbent article adapted to beworn about a lower torso of a human body, comprising: a chassis forminga waist opening and a pair of leg openings and having longitudinallyopposing first and second waist end edges, longitudinally opposing firstand second waist regions adjacent to the respective waist end edge, anda crotch region longitudinally intermediate of the waist regions, thechassis comprising a topsheet having a wearer-facing surface disposedsuch that at least a portion of the wearer-facing surface contacts thebody when the article is worn and a backsheet defining a garment-facingsurface of the article; a non-removable absorbent core componentdisposed in the crotch region between the topsheet and the backsheet;and a first replaceable absorbent core component disposed between thetopsheet and the backsheet and in capillary liquid communication withthe non-removable absorbent core component, the first replaceableabsorbent core component having an outer end segment comprising a liquidimpervious layer; the chassis being adapted to allow removal andreplacement of the first replaceable absorbent core component with asecond replaceable absorbent core component, and for continued usefollowing such replacement.